Patch-like infusion device

ABSTRACT

A system and method for a patch-like, self-contained substance infusion device ( 700 ) which can be attached to a skin surface via an adhesive contact surface. A push button ( 780 ) activation assembly can then be used to remove an interlock ( 730 ), allowing a disk or Belleville spring ( 735 ) assembly to apply an essentially even and constant pressure to the contents of a fluid reservoir assembly ( 710 ). This allows the release of one or more spring-loaded patient needles ( 760 ) into the skin surface, and establishes a fluid communication path between the patient needles ( 760 ) and the pressurized fluid reservoir contents thereby delivering an infusion into the skin. The push button ( 780 ) activation assembly further allows the release of one or more improved safety mechanisms ( 794 ) after use.

FIELD OF THE INVENTION

The present invention relates generally to a substance delivery devicehaving improved valve, spring and safety mechanisms and to a patch-like,self-contained substance infusion device that can be used to deliver avariety of substances or medications to a patient. This applicationclaims the benefit under 35 U.S.C. §119(e) of a U.S. provisional patentapplication of Chris Cindrich et al. entitled “Patch-Like InfusionDevice”, Ser. No. 60/494,286, filed on Aug. 12, 2003, and of a U.S.provisional patent application of Chris Cindrich et al. entitled“Patch-Like Infusion Device With Improved Valve, Spring And SafetyMechanisms”, Ser. No. 60/558,611, filed Apr. 2, 2004, the entire contentof each of said applications being incorporated herein by reference.This application contains subject matter which is related to that of aU.S. nonprovisional patent application of Charles D. Shermer et al.entitled “Patch-Like Infusion Device”, Ser. No. 10/623,702, filed onJul. 22, 2003, the entire content of which is incorporated herein byreference.

BACKGROUND OF THE INVENTION

A very large number of people, such as those suffering from conditionssuch as diabetes use some form of infusion therapy, such as dailyinsulin infusions to maintain close control of their glucose levels.Currently, in the insulin infusion treatment example, there are twoprincipal modes of daily insulin therapy. The first mode includessyringes and insulin pens. These devices are simple to use and arerelatively low in cost, but they require a needle stick at eachinjection typically three to four times per day. The second modeincludes infusion pump therapy, which entails the purchase of anexpensive pump that lasts for about three years. The initial cost of thepump is a high barrier to this type of therapy. From a user perspective,however, the overwhelming majority of patients who have used pumpsprefer to remain with pumps for the rest of their lives. This is becauseinfusion pumps, although more complex than syringes and pens, offer theadvantages of continuous infusion of insulin, precision dosing andprogrammable delivery schedules. This results in closer glucose controland an improved feeling of wellness.

As patients on oral agents eventually move to insulin and their interestin intensive therapy increases, users typically look to insulin pumps.However, in addition to their high cost (roughly 8 to 10 times the dailycost of syringe therapy) and limited lifetime, insulin pumps representrelatively old technology and are cumbersome to use. Also, from alifestyle standpoint, the tubing (known as the “infusion set”) thatlinks the pump with the delivery site on the user's abdomen is veryinconvenient and the pumps are relatively heavy, making carrying thepump a burden.

Therefore interest in better therapy is on the rise, accounting for theobserved growth in pump therapy and increased number of dailyinjections. In this and similar infusion examples, what is needed tofully meet this increased interest is a form of insulin delivery orinfusion that combines the best features of daily injection therapy (lowcost and ease of use) with those of the insulin pump (continuousinfusion and precision dosing) and that also avoids the disadvantages ofeach.

Several attempts have been made to provide ambulatory or “wearable” druginfusion devices that are low in cost and convenient to use. Some ofthese devices are intended to be partially or entirely disposable. Intheory, devices of this type can provide many of the advantages of aninfusion pump without the attendant cost and inconvenience.Unfortunately, however, many of these devices suffer from disadvantagesincluding user discomfort (due to the gauge and/or length of injectionneedle used), compatibility and interaction between the substance beingdelivered and the materials used in the construction of the infusiondevice, and possible malfunctioning if not properly activated by theuser (e.g., “wet” injections resulting from premature activation of thedevice). Difficulties in manufacturing and in controlling needlepenetration depth have also been encountered, particularly when shortand/or fine-gauge injection needles are used. The possibility ofneedle-stick injuries to those who come into contact with the useddevice has also been problematic.

Accordingly, a need exists for an alternative to current infusiondevices, such as infusion pumps for insulin, that further providessimplicity in manufacture and use improvements for insulin andnon-insulin applications.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a patch-like infusiondevice which can be conveniently worn against the skin while providinginfusion of a desired substance, and providing minimal discomfort byusing one or more microneedles.

Another object of the present invention is to provide a patch-likeinfusion device which provides a hidden patient needle or needles priorto and during use, unlike a conventional syringe.

Another object of the present invention is to provide a patch-likeinfusion device which can be secured to a patient via an adhesivesurface, and thereafter allows the pressurizing of a content reservoir,patient needle implantation and reservoir content delivery through anactivation step.

Another object of the present invention is to provide a patch-likeinfusion device which provides pressurizing a content reservoir using abladder and Belleville or other disk-type spring assembly.

Another object of the present invention is to provide a patch-likeinfusion device which allows pressurizing the contents of a contentreservoir by removing a Belleville spring retaining disk.

Another object of the present invention is to provide a patch-likeinfusion device which can be activated via a reasonable force applied toa vertical or horizontal push surface in an activation step.

Another object of the present invention is to provide a patch-likeinfusion device which allows for visual inspection of the devicecontents before, during and after use.

Another object of the present invention is to provide a patch-likeinfusion device which allows for removal of a patient needle cap and/oradhesive cover in one or more motions.

Another object of the present invention is to provide a patch-likeinfusion device which facilitates self-injection and reduces oreliminates variations in injection techniques between users

Another object of the present invention is to provide a patch-likeinfusion device which includes improved shielding mechanisms forprotecting the patient needle or needles upon intentional or accidentalremoval from the skin surface.

Another object of the present invention is to provide a patch-likeinfusion device which includes improved valve mechanisms for providing asterile barrier and pressure seal prior to and during device use.

Another object of the present invention is to provide a patch-likeinfusion device which includes improved Belleville spring and spring pinmechanisms for use with the infusion device.

Another object of the present invention is to provide a patch-likeinfusion device which includes improved molding techniques to betterutilize construction materials.

Another object of the present invention is to provide a patch-likeinfusion device which includes improved microneedle constructiontechniques and materials.

Another object of the present invention is to provide a patch-likeinfusion device which includes improved activation mechanisms includingpivot arms and magnetic apparatus.

Another object of the present invention is to provide a patch-likeinfusion device which includes improved manifold spring mechanisms.

Another object of the present invention is to provide a patch-likeinfusion device which includes improved fill mechanisms, fill indicatorsand sterile packaging.

These and other objects are substantially achieved by providing a systemand method for a patch-like, wearable, self-contained substance infusiondevice which provides one or more substantially hidden patient needleswhich can be placed in fluid communication with a content reservoirassembly that includes a rigid bladder portion used in conjunction witha non-distensible bladder film, such as a metallized film. A push typeactivation assembly is provided which can then be used to remove aretaining pin and allow a Belleville spring assembly to apply anessentially even and constant pressure to the contents of a reservoirassembly. The push type activation assembly then releases and seats oneor more spring-loaded patient needles into the patient's skin andestablishes a fluid communication path between the patient needles andthe pressurized reservoir contents, thereby delivering an infusion ofcontents into the skin of the user. Upon completion and removal of theinfusion device, a number of safety mechanisms can be engaged to coverthe needles for disposal.

BRIEF DESCRIPTION OF THE DRAWINGS

The various objects, advantages and novel features of the preferredembodiments of the present invention will be more readily appreciatedfrom the following detailed description when read in conjunction withthe appended drawings, in which:

FIG. 1 is a cross-sectional view of a first embodiment of a patch-likeinjector or infusor system using a side push button surface prior toactivation;

FIG. 2 is another cross-sectional view of the first embodiment of apatch-like injector or infusor system using a side push button surfacesubsequent to activation;

FIG. 3 is a cross-sectional view of a reservoir subassembly of thepatch-like injector or infusor system of FIG. 1;

FIG. 4 is a cross-sectional view of a Belleville spring subassembly ofthe patch-like injector or infusor system of FIG. 1;

FIG. 5 is a cross-sectional view of a first embodiment of a push valvesubassembly of the patch-like injector or infusor system of FIG. 1 in aclosed position;

FIG. 6 is a cross-sectional view of the first embodiment of the pushvalve subassembly of the patch-like injector or infusor system of FIG. 1in an open position;

FIG. 7 is a cross-sectional view of a second embodiment of a pull valvesubassembly of the patch-like injector or infusor system of FIG. 1;

FIG. 8 is a cross-sectional view of a third embodiment of a push/pullvalve subassembly of the patch-like injector or infusor system of FIG.1;

FIG. 9 is a cross-sectional view of a second embodiment of a patch-likeinjector or infusor system using a top push button surface prior toactivation;

FIG. 10 is a cross-sectional view of the second embodiment of apatch-like injector or infusor system of FIG. 9 subsequent toactivation;

FIG. 11 is a top view from a first perspective angle of the reservoirsubassembly of the second embodiment of a patch-like injector or infusorsystem of FIG. 9;

FIGS. 12 and 13 are exploded views of another version of the secondembodiment of the patch-like injector or infusor system using a top pushbutton surface;

FIG. 14 is a top view from a first perspective angle of the patch-likeinjector or infusor system of FIG. 12 prior to activation;

FIG. 15 is a cross-sectional view of the patch-like injector or infusorsystem of FIG. 12 prior to activation;

FIG. 16 is a side elevational view of the patch-like injector or infusorsystem of FIG. 12 prior to activation;

FIG. 17 is another cross-sectional view of the patch-like injector orinfusor system of FIG. 12 prior to activation;

FIG. 18 is a top view from a first perspective angle of the patch-likeinjector or infusor system of FIG. 12 subsequent to activation;

FIG. 19 is a cross-sectional view of the patch-like injector or infusorsystem of FIG. 12 subsequent to activation;

FIG. 20 is a side elevational view of the patch-like injector or infusorsystem of FIG. 12 subsequent to activation;

FIG. 21 is another cross-sectional view of the patch-like injector orinfusor system of FIG. 12 subsequent to activation;

FIGS. 22( a) through 22(e) are multiple views of the reservoirsubassembly of the patch-like injector or infusor system of FIG. 12;

FIG. 23 is a cross-sectional view of a valve subassembly of thepatch-like injector or infusor system of FIG. 12 in a closed position;

FIG. 24 is a cross-sectional view of a valve subassembly of thepatch-like injector or infusor system of FIG. 12 in an open position;

FIG. 25 is an exploded view of a third embodiment of a patch-likeinjector or infusor system;

FIG. 26 is a cross-sectional view of the patch-like injector or infusorsystem of FIG. 25 prior to activation;

FIG. 27 is a cross-sectional view of the patch-like injector or infusorsystem of FIG. 25 subsequent to activation;

FIG. 28 is a top view from a first perspective angle of a fourthembodiment of a patch-like injector or infusor system prior toactivation;

FIG. 29 is another top view from a second perspective angle of thepatch-like injector or infusor system of FIG. 28 subsequent toactivation and prior to retraction;

FIG. 30 is another top view from a third perspective angle of thepatch-like injector or infusor system of FIG. 28 subsequent toactivation and prior to retraction;

FIG. 31 is another top view from a fourth perspective angle of thepatch-like injector or infusor system of FIG. 28 subsequent toretraction;

FIG. 32 is a cross-sectional view of a valve subassembly of thepatch-like injector or infusor system of FIG. 28 in a closed position;

FIG. 33 is a cross-sectional view of a valve subassembly of thepatch-like injector or infusor system of FIG. 28 in an open position;

FIG. 34 is a top view from a first perspective angle of another versionof the fourth embodiment of a patch-like injector or infusor system;

FIG. 35 is another top view from a second perspective angle of thepatch-like injector or infusor system of FIG. 34;

FIG. 36 is top view from a first perspective angle of still anotherversion of the fourth embodiment of a patch-like injector or infusorsystem;

FIG. 37 is a cross-sectional view of a fifth embodiment of a patch-likeinjector or infusor system;

FIGS. 38 through 41 are cross-sectional views of the patch-like injectoror infusor system of FIG. 37 with extended safety;

FIGS. 42 and 43 are top views of the reservoir subassembly of thepatch-like injector or infusor system of FIG. 37;

FIGS. 44 through 48 are cross-sectional views of the reservoir and valvesubassembly of the patch-like injector or infusor system of FIG. 37;

FIG. 49 is a cross-sectional view of a two-shot patient needle manifoldsubassembly of the patch-like injector or infusor system of FIG. 37;

FIGS. 50 through 54 are views from a first perspective angle of assemblysteps of the patch-like injector or infusor system of FIG. 37;

FIGS. 55 through 60 are cross-sectional views of a Belleville spring andfollower;

FIG. 61 is a cross-sectional view of a first variation of an improvedvalve embodiment in a closed position;

FIG. 62 is a cross-sectional view of a second variation of an improvedvalve embodiment in a closed position;

FIG. 63 is a cross-sectional view of a third variation of an improvedvalve embodiment in a closed position;

FIG. 64 is an enlarged cross-sectional view of a fourth variation of animproved valve embodiment in a closed position;

FIG. 65 is an enlarged cross-sectional view of a fifth variation of animproved valve embodiment wherein the opening includes tapered surfaces;

FIG. 66 is a cross-sectional view of the improved valve embodiment ofFIG. 65 in a closed position;

FIG. 67 is another cross-sectional view of the improved valve embodimentof FIG. 65 in a closed position;

FIG. 68 is a cross-sectional view of the improved valve embodiment ofFIG. 65 in an open position and wherein the opening includes bothtapered and flat surfaces;

FIGS. 69 through 71 are views of an improved valve plunger rodembodiment;

FIGS. 72 through 74 are views of an improved overmolded valve plungerrod embodiment;

FIG. 75 is a view of an improved rotating valve embodiment;

FIG. 76 is a detailed cross-sectional view of the improved rotatingvalve embodiment of FIG. 75;

FIG. 77 is a cross-sectional view of another version of an improvedrotating valve embodiment and fill cap;

FIG. 78 is a perspective view of another improved rotating valveembodiment;

FIGS. 79( a) through 79(c) are cross-sectional views of a first, secondand third stage of the fluid path of the improved rotating valveembodiment of FIG. 77;

FIG. 80 is a cross-sectional view of an improved valve subassembly in aclosed position;

FIG. 81 is a cross-sectional view of the improved valve subassembly ofFIG. 80 in an open position;

FIG. 82 is a cross-sectional view of an improved Belleville spring andpin embodiment in a secured position;

FIG. 83 is a cross-sectional view of the improved Belleville spring andpin embodiment of FIG. 82 in a released position;

FIGS. 84( a) through 84(c) are perspective views of a first, second andthird improved Belleville spring and pin embodiment configuration;

FIG. 85 is a force vector diagram of an improved Belleville spring andpin embodiment configuration;

FIG. 86 is a cross-sectional view of an improved Belleville spring andpin embodiment in a secured position within an example infusion deviceto illustrate button induced pin release;

FIG. 87 is a cross-sectional view of the improved Belleville spring andpin embodiment of FIG. 86 in a released position;

FIG. 88 is a cross-sectional view of an improved Belleville spring andsplit ring pin embodiment;

FIG. 89 is a second cross-sectional view of the improved Bellevillespring and split ring pin embodiment of FIG. 88;

FIG. 90 is a perspective view of an overmolded Belleville spring inaccordance with an embodiment of the present invention;

FIGS. 91 and 92 are cross-sectional views of the overmolded Bellevillespring of FIG. 90 in a released and flexed position, respectively;

FIG. 93 is a cross-sectional view of a device embodiment usingBelleville spring and pin friction to hold the device in a pre-activatedstate;

FIG. 94 is a top view of an improved reservoir embodiment of a device;

FIG. 95 is a top view of an improved arm/fluid path embodiment of adevice;

FIG. 96 is a perspective view of the improved arm/fluid path embodimentof FIG. 95;

FIG. 97 is an assembly diagram of the improved reservoir and arm/fluidpath embodiment of FIGS. 94 and 95 in a disassembled position;

FIG. 98 is an assembly diagram of the improved reservoir and arm/fluidpath embodiment of FIGS. 94 and 95 in an assembled position;

FIG. 99 is a cross-sectional view of a first sealing device for thereservoir and arm/fluid path assembly embodiment of FIG. 98;

FIG. 100 is a cross-sectional view of a second sealing device for thereservoir and arm/fluid path assembly embodiment of FIG. 98;

FIGS. 101 through 105 are cross-sectional views of construction examplesof a patient needle manifold;

FIG. 106 is a cross-sectional view of an improved patient needle hub andmanifold;

FIG. 107 is a view of a porous patient microneedle;

FIG. 108 is a view of a patient microneedle having a number of sideholes;

FIGS. 109 and 110 are cross-sectional views of a device having a pivotarm assembly;

FIGS. 111 through 115 are cross-sectional views of a device having amagnetic activation assembly;

FIGS. 116( a) through 116(c) are illustrative views of a scotch-yokefunction safety embodiment;

FIG. 117 is a perspective view of a retraction wedge shield in aretracted state;

FIG. 118 is a perspective view of the retraction wedge shield of FIG.117 in an extended state;

FIG. 119 is a perspective view of the carriage return mechanism of theshield of FIG. 117;

FIG. 120 is a perspective view of a retraction-slot shield in an initialposition;

FIG. 121 is a perspective view of the retraction-slot shield of FIG. 120in an in-use position;

FIG. 122 is a perspective view of the retraction-slot shield of FIG. 120in a retracted position;

FIG. 123 is a perspective view of a bucket shield in a retracted state;

FIG. 124 is a perspective view of the bucket shield of FIG. 123 in anextended state;

FIG. 125 is a perspective internal view of the bucket shield of FIG. 123in a retracted state within an unactivated device;

FIG. 126 is a perspective internal view of the bucket shield of FIG. 123in a retracted state within an activated device;

FIG. 127 is a perspective internal view of the bucket shield of FIG. 123in an extended state within an activated device;

FIG. 128 is a perspective view of a ratchet-lock shield in a retractedstate;

FIG. 129 is a perspective view of the ratchet-lock shield of FIG. 128 inan extended state;

FIG. 130 is a perspective view of the ratchet-lock mechanism of theshield of FIG. 128;

FIG. 131 is a perspective view of a pull-out shield in a retractedstate;

FIG. 132 is a perspective view of the pull-out shield of FIG. 131 in anextended state;

FIG. 133 is a perspective view of another pull-out shield in a retractedstate;

FIG. 134 is a perspective view of the pull-out shield of FIG. 133 in anextended state;

FIG. 135 is a perspective view of a torsion-spring shield in an initialposition;

FIG. 136 is a perspective view of the torsion-spring shield of FIG. 135in an in-use position;

FIG. 137 is a perspective view of the torsion-spring shield of FIG. 135in a retracted position;

FIG. 138 is a perspective view of a hinged shield with an integralspring;

FIG. 139 is a perspective view of a hinged shield with an adhesivedriven hinge;

FIG. 140 is a perspective view of a spring shield with a circularintegral spring;

FIG. 141 is a perspective view of a spring shield with a buckle-typeintegral spring;

FIG. 142 is a view illustrating an over-rotating shield;

FIG. 143 is a cross-sectional view illustrating a cam-action safety in aready state;

FIG. 144 is a cross-sectional view of the cam-action safety of FIG. 143in a cocked state;

FIG. 145 is a cross-sectional view of the cam-action safety of FIG. 143in a fired state;

FIG. 146 is a cross-sectional view of the cam-action safety of FIG. 143in a safe state;

FIG. 147 is a cross-sectional view of another cam-action mechanism;

FIGS. 148 and 149 are perspective views of a flip shield;

FIG. 150 is a perspective view of an improved manifold spring in anunactivated position;

FIG. 151 is another perspective view of the manifold spring of FIG. 150in an unactivated position installed within an exemplary device;

FIG. 152 is a perspective view of the manifold spring of FIG. 150 in anactivated position;

FIG. 153 is a perspective view of another improved manifold spring in anunactivated position installed within an exemplary device;

FIG. 154 is a perspective view of the manifold spring of FIG. 153 in anactivated position;

FIG. 155 is a perspective view of another improved manifold spring in anunactivated position;

FIG. 156 is a perspective view of the manifold spring of FIG. 155 in anactivated position;

FIG. 157 is a cross-sectional view showing a fill hole provided by thebutton;

FIG. 158 is a cross-sectional view showing a valve assembly in placeafter filling;

FIG. 159 is a cross-sectional view showing the closing of the buttonwindow after filling of the valve assembly of FIG. 158;

FIG. 160 is a cross-sectional view showing the closed window of thevalve assembly of FIG. 158;

FIG. 161 is a view showing valve, button valve hole and button alignmentbefore rotation;

FIG. 162 is a view showing valve, button valve hole and button alignmentafter rotation;

FIG. 163 is a cross-sectional view showing valve, button valve hole andbutton alignment after rotation;

FIG. 164 is a top view of a reservoir illustrating a sign visible beforeinjection;

FIG. 165 is a side view of the reservoir of FIG. 164 illustrating a signvisible before injection;

FIG. 166 is a top view of a reservoir illustrating an absent sign afterinjection;

FIG. 167 is a side view of the reservoir of FIG. 166 illustrating anabsent sign after injection;

FIG. 168 is an isometric view of a nest-type packaging system whenempty;

FIG. 169 is an isometric view of the nest-type packaging system of FIG.168 when filled;

FIG. 170 is an isometric view of the nest-type packaging system of FIG.168 having four devices for filling;

FIG. 171 is an isometric view of the nest-type packaging system of FIG.168 having four devices in an up position for filling;

FIG. 172 is a cross-sectional view of the nest-type packaging system ofFIG. 168;

FIG. 173 is a top view of the nest-type packaging system of FIG. 168when filled;

FIG. 174 is a cross-sectional view of the nest-type packaging system ofFIG. 168 in double bags; and

FIG. 175 is a cross-sectional view of the nest-type packaging system ofFIG. 168 when boxed and bagged.

Throughout the drawings, like reference numerals will be understood torefer to like parts, components or structures.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The embodiments of the present device described below can be used as aconvenient, patch-like device to deliver a pre-measured dose of asubstance, such as a drug or medication, to a user through an adhesiveattached infusion device. The device is self-contained and is attachedto the skin surface of the user by adhesive disposed on a bottomsurface. Once properly positioned and activated by the user, thepressure of a released Belleville spring or other disk-type spring on areservoir surface within the device can be used to empty the contents ofthe flexible reservoir through one or more patient microneedles via aneedle manifold. The substance within the reservoir is then deliveredthrough the skin of the user by the microneedles which are driven intothe skin. It will be understood that other embodiments are possible inwhich the Belleville or disk spring is replaced with a different type ofstored energy device which may be mechanical, electrical and/or chemicalin nature.

As will be appreciated by one skilled in the art, there are numerousways of carrying out the patch-like injection or infusor systemdisclosed herein. Although reference will be made to the embodimentsdepicted in the drawings and the following descriptions, the embodimentsdisclosed herein are not meant to be exhaustive of the variousalternative designs and embodiments that are encompassed by thedisclosed invention. In each disclosed embodiment, the device isreferred to as an infusor; however, the device may also injectsubstances at a much faster bolus rate than is commonly accomplished byinfusor devices. For example, the contents can be delivered in a periodas short as several seconds, or as long as several days.

In a first embodiment of the device, shown in FIGS. 1 through 4, apush-button design 100 is shown wherein the activation and energizing ofthe device is accomplished in a single multi-function/step process. FIG.1 is cross-sectional view of a first embodiment of a patch-like injectoror infusor system using a side push button in an unactivated state, FIG.2 is cross-sectional view of the embodiment shown in an activated state,FIG. 3 is cross-sectional view of the reservoir subassembly of theembodiment shown in FIG. 1, and FIG. 4 is cross-sectional view of theBelleville spring assembly of the embodiment shown in FIG. 1.

The device of FIGS. 1 through 4 includes a push button 105, an upperhousing 110, a lower housing 115, a reservoir valve assembly 120, aBelleville spring 130, a spring retention disk 135, a manifold assembly140, at least one patient needle 141 and a reservoir 150. The device canfurther include a needle shield 111, which protects the needles 141 andis removed before use. The push button includes at least one inclinemember 106 which has an inclined surface 107 to engage the outerdiameter 136 of the disk 135 as the button 105 moves during activation.As the button 105 is pushed inward as shown in FIG. 2, the incline 107displaces at least one side of the disk 135 upward, which results in aninner diameter 137 of the disk being displaced downward. In doing so,the inner diameter 137 of the disk 135 is pulled from the center of theBelleville spring 130, releasing the spring 130 to then apply a force toa flexible member 151 of the reservoir 150, compressing the contentsagainst a rigid member 152 of the reservoir 150. As shown in FIG. 4, thereservoir 150 includes a flexible member 151 and a rigid member 150adjacent to a Belleville spring 130. The Belleville spring 130 is heldaway from the flexible member 151 through an interference fit with theprotruding inner diameter 137 of disk 135.

The button 105 further includes a surface 108 to contact a valve member121 of the valve assembly 120 to establish a flow path between thereservoir 150 and the patient needle 141. As shown in FIG. 3, thepush-pull type valve assembly 120 establishes a flow path between areservoir outlet 153 and a outer circumference fluid path 154, when thevalve member 121 is pushed inward. When pushed inward, an enlarged valvemember end 122 is displaced from a pocket 123, allowing flow from thereservoir 150, around a reduced diameter of the valve member 121, andinto the fluid path 154 towards the manifold assembly 140, and needle141 therein. The fluid path 154 is provided within a fluid path arm 155which can also be used to urge the needle manifold 140.

As the push button 105 is pushed inward, a support member 109 is movedfree of a shoulder 142 of the manifold assembly 140, allowing themanifold assembly 140 to be driven downward toward a patient's skinsurface (not shown). The manifold assembly can be driven by a number ofmeans, such as coil springs, or through the flex characteristics of theouter diameter fluid path arm 155. The fluid path arm 155 can beconfigured to force the manifold assembly 140 when released by thesupport member 109.

In the embodiment shown in FIGS. 1 through 4, as the push button 105 ispushed, three functions are achieved in an ordered and/or simultaneousfashion. First, the movement of the push button 105 opens at least onevalve assembly 120 allowing fluid communication between the reservoir150 and the patient needles 141. Second, the movement of the push button105 dislodges the spring retention disk 135, releasing the Bellevillespring 130, and third, the movement of the push button 105 removes thesupport member 109 from the patient needle manifold 140 allowing themanifold 140 to travel as urged by a means, such as the fluid path arm155 or a manifold spring (not shown).

Specifically, the push button 105 includes the series of inclines 107which engage the spring retention disk 135 as the push button 105 isslidably moved, and release the Belleville spring 130 therebypressurizing the contents of the reservoir 150. The push button 105 alsoengages the push valve 120, initiating flow between the now pressurizedreservoir 150 and the manifold assembly 140. The push button 105 furtherremoves or displaces one or more support members 109 from the patientneedle manifold assembly 140, allowing the manifold 140 to be driven bya drive means, such as the fluid path arm 155 or one or more drivesprings (not shown), and seat the patient needles 141.

The push/pull valve assembly 120 of the embodiment shown in FIG. 1 isconstructed to restrict flow between the reservoir chamber (i.e., asprovided between elements 151 and 152 of the reservoir 150), and thepatient needle manifold 140 until pushed into an open position by thepush button 105, and can be comprised of any number of valve assemblies120, 222, 242 and 262, as described in greater detail below.

A first embodiment of a push valve assembly 222 is shown in FIGS. 5 and6. FIG. 5 is cross-sectional view of the valve assembly in a closedposition and FIG. 6 is cross-sectional view of the valve assembly ofFIG. 5 in an open position. The valve assembly 222 includes a plasticbutton 223 slidably engaged within a rubber stopper 224 in fluidcommunication with the reservoir 150. The valve assembly 222 has as aninitial state and an activated state, and includes a large diameterdistal end having a distal set of radially projecting fins, or ribs 225,and a reduced diameter proximal end having a proximal set of detents226. In the initial state, the valve 222 distal ribs 225 serve toprevent microbial ingress into the fluid path 227, and the proximaldetents create a seal to trap the drug safely within the reservoir 150.Both sets of ribs 225 and detents 226 are performing critical tasks inpreventing fluid loss from inside the reservoir over long periods oftime as well as preventing contamination of the drug from outside thereservoir over the same period of time.

In use, the button 223 will eventually be pushed into an activated stateby the movement of the push button 105 and the set of detents will beadvanced from engagement with the rubber stopper 124, which permits thedrug to flow from the reservoir 150, past the detents 226 and into thevalve fluid path 154. At the same time, the distal set of ribs 225 areby nature also pushed in and the location of the ribs 225 themselvestranslate into a position such that they direct the fluid from thereservoir 150, through the valve fluid path 227, and down the fluid path154 to the patient needle manifold (not shown).

In the position shown in FIG. 5, the plastic button 223 includes thereduced diameter proximal end having detents 226 seated securely withinthe rubber stopper 124 and prevents any fluid escaping the reservoir150. As the plastic button 223 is engaged and displaced within therubber stopper 224 by the push button 105, an opening is created at theproximal end which allows fluid communication from the reservoir 150 asshown by the arrow in FIG. 6. The valve assembly 222 can be included inthe reservoir subassembly 150, such that a continuous fluid path 154 canbe provided by the reservoir subassembly 150 between the reservoircontents and the patient microneedles 141.

A second embodiment of a valve assembly 242 is shown in FIG. 7. FIG. 7is cross-sectional view of the second valve assembly embodiment in anopen position. The valve assembly 242 includes a plastic button 247, andis configured to operate as a pull valve. As shown in FIG. 7, whenpushed forward, the plastic button 247 mateably engages the reservoir150 opening and prevents fluid communication from the reservoir 150.When pulled from the reservoir 150 opening, the gap produced allowsfluid communication along the conical face of the button 247 and to thefluid path 154 toward the patient needle manifold (not shown).

The valve assembly 242 has as an initial state and an activated state,and includes a large diameter distal end having a distal set of detents243, a conical section 244 and a reduced diameter proximal end 245. Inthe initial state, the valve 242 distal detents 243 serve to preventmicrobial ingress into the fluid path 246, and the conical section 244and proximal end 245 create a seal to trap the drug safely within thereservoir 150. Each of the detents 243, conical section 244 and reduceddiameter proximal end 245 prevent fluid loss from inside the reservoir150 over long periods of time as well as prevent contamination of thedrug from outside the reservoir over the same period of time.

In use, the button 247 will eventually be pulled into an activated stateby the movement of an alternate push button version (not shown) and theconical section 244 and reduced diameter proximal end 245 will beadvanced from engagement with the reservoir 150 opening, which permitsthe drug to flow from the reservoir 150, past the reduced diameterproximal end 245 and into the valve fluid path 246. At the same time,the distal set of detents 243 translate into a position such that theydirect the fluid from the reservoir 150, through the valve fluid path246, and down the fluid path 154 to the patient needles (not shown).

A third embodiment of a valve assembly 262 is shown in FIG. 8. FIG. 8 iscross-sectional view of the third valve assembly embodiment in an openposition, and includes a plastic member 263, configured to operate aseither a push or pull valve. As shown in FIG. 8, when pulled outward,the plastic member 263 obstructs the reservoir opening and preventsfluid communication from the reservoir 150. When pushed forward theplastic member aligns an opening and allows fluid communication betweenthe reservoir 150 and the patient needle manifold 140 (not shown).

The valve assembly 262 has as an initial state and an activated state,and includes a distal end having a distal set of detents 264, and anenlarged diameter proximal end 265. In the initial state, the valve 262distal detents 264 serve to prevent microbial ingress into the fluidpath 267, and the enlarged proximal end 265 creates a seal with the end266 of a plug insert member 270 to trap the drug safely within thereservoir 150. Each of the detents 264, and the enlarged diameterproximal end 265 prevent fluid loss from inside the reservoir 150 overlong periods of time as well as prevent contamination of the drug fromoutside the reservoir over the same period of time.

In use, the member 263 will eventually be pushed into an activated stateby the movement of a the push button 105 and the enlarged proximal end265 will be advanced from engagement with the end 266 of the plug insertmember 270, which permits the drug to flow from the reservoir 150, pastthe enlarged proximal end 265 and into the valve fluid path 267. At thesame time, the distal set of detents 264 translate into a position suchthat they direct the fluid from the reservoir 150, through the valvefluid path 267, and down the fluid path 154 through openings 268 and 269to the patient needles (not shown).

In a second embodiment of the device, shown in FIGS. 9 through 11, apush-button design 280 is shown wherein activation of the device is alsoaccomplished in a single multi-function/step process but the needlemanifold and reservoir assembly, are rotated about a hinge disposed at apoint opposite the needle manifold. FIG. 9 is cross-sectional view ofthe second embodiment of a patch-like injector or infusor system using atop push button surface in an unactivated state, FIG. 10 iscross-sectional view of the second embodiment shown in an activatedstate, and FIG. 11 is top view of the reservoir subassembly of theembodiment shown in FIGS. 9 and 10. As with the first embodiment, asingle step can be used to activate the device.

The device of FIGS. 9 through 11 includes an upper housing 281, a lowerhousing 282, a Belleville spring 283, a spring retention disk 284, amanifold assembly 285, at least one patient needle 286 and a reservoir287 having a flexible member 289 and a rigid member 288. In theembodiment shown in FIGS. 9 through 11, the Belleville spring 283 isheld and subsequently released by the disk 284 and compressing thereservoir 287 substantially similar to the spring 130, disk 135 andreservoir 150 of FIG. 1, but in an inverted position, such that therigid member 288 of the reservoir 287 is constructed including themanifold assembly 285 at a first end, and a hinge mechanism 291 at asecond end.

In the embodiment of FIGS. 9 through 11, through a release means, suchas a button (not shown), the hinged reservoir 287 is released, therebyreleasing the Belleville spring 283 to then apply a force to theflexible member 289 of the reservoir 287, compressing the contentsagainst the rigid member 288 of the reservoir 287. As shown in FIG. 10,when released, a spring 290 drives the manifold assembly 285 andreservoir 287 downward toward a patient's skin surface (not shown) andaway from the disk 284, releasing the Belleville spring 283 andpressurizing the reservoir contents. Any number of valve assemblies canbe used to establish the fluid path between the reservoir 287 and themanifold 285.

In the embodiment shown in FIGS. 9 through 11, upon release, theBelleville spring 283, manifold assembly 285, patient needle 286 andreservoir 287 are rotated into an activated and in-use position, and thedesired three functions are achieved in an ordered and/or simultaneousfashion. First and second, the activation allows the spring 290 torotate the reservoir 287 and manifold 285, which dislodges the springretention disk 284, releasing the Belleville spring 283 and initiatingflow from the reservoir 287. Third, the activation further allows themanifold 285 to travel as urged by the manifold spring 290 and seat theneedles 286.

Another version of the second embodiment is shown in FIGS. 12 through24. In the version of the second embodiment shown in FIGS. 12 through24, a push-button design 300 is shown wherein the activation of thedevice is accomplished in a single multi-function/step process. FIGS. 12and 13 are exploded views of the second embodiment of a patch-likeinjector or infusor system using a top push button surface to allow auser to press down upon an upper housing 305 and rotate the device intoan activated and in-use position. FIGS. 14 through 17 are views of thesecond embodiment of the patch-like injector or infusor system of FIG.12 prior to activation. FIGS. 18 through 21 are views of the secondembodiment of the patch-like injector or infusor system of FIG. 12subsequent to activation. FIGS. 22( a) through 22(e) are multiple viewsof the reservoir subassembly of the patch-like injector or infusorsystem of FIG. 12. FIGS. 23 and 24 are views of the reservoirsubassembly and valve subassembly of the patch-like injector or infusorsystem of FIG. 12 in a closed and open position, respectively.

As shown in FIGS. 12 and 13, the second embodiment of the presentinvention comprises an infusion device 300 having an upper housing 305,a Belleville spring retention disk 310, at least one Belleville spring315, a reservoir film 320, a reservoir subassembly 325, at least onepatient microneedle 340, and a lower housing 350. The reservoirsubassembly 325 further includes a valve spool 326 and valve seat 328,and a pivot mechanism 327, such as a pin. The pivot mechanism 327 isreceived by at least one pin opening 329 disposed on the lower housingallowing the upper housing 305, Belleville spring retention disk 310,Belleville spring 315, reservoir film 320, reservoir subassembly 325,and patient microneedle 340 to rotate into an activated and in-useposition. A user can press upon the upper housing 305 to release theBelleville spring 315 from the disk 310, which then applies a force tothe flexible member 320, compressing the contents against the reservoirsubassembly 325. The motion of the user further drives the patientmicroneedles 340 downward toward a patient's skin surface (not shown)and away from the disk 310. Simultaneously, the user can activate a pushor pull type valve subassembly (i.e., valve spool 326 and valve seat328) described in greater detail below with reference to FIGS. 23 and24, to establish the fluid path between the reservoir and the patientmicroneedles 340.

FIGS. 14 through 17 are views of the device 300 of FIG. 12 prior toactivation. FIG. 14 is an isometric view illustrating the rotatingcomponents (i.e., the upper housing 305, Belleville spring retentiondisk 310, Belleville spring 315, reservoir film 320, reservoirsubassembly 325, and patient microneedles 340) prior to being rotatedinto an activated and in-use position about the lower housing 350. FIG.15 is a cross-sectional view illustrating the positioning of therotating components before activation and placement into the in-useposition. FIG. 16 is a side elevational view illustrating the separationof the rotating components from the lower housing 350 before activationand placement into the in-use position.

FIGS. 18 through 21 are views of the device 300 of FIG. 12 subsequent toactivation. FIG. 18 is an isometric view illustrating the rotatingcomponents (i.e., the upper housing 305, Belleville spring retentiondisk 310, Belleville spring 315, reservoir film 320, reservoirsubassembly 325, and patient microneedles 340) rotated into an activatedand in-use position about the lower housing 350. FIG. 19 is across-sectional view illustrating the positioning of the rotatingcomponents after activation and placement into the in-use position. FIG.20 is a side elevational view illustrating the engagement of therotating components with the lower housing 350 after activation andplacement into the in-use position.

FIGS. 22( a) through 22(e) are multiple views of the reservoirsubassembly of the device 300 of FIG. 12. FIG. 22( a) is a top view ofthe reservoir subassembly of the device 300 of FIG. 12. FIG. 22( b) is afirst side view, FIG. 22( c) is a second side view, and FIG. 22( d) is athird side view of the reservoir subassembly of the device 300 of FIG.12. FIG. 22( e) is a bottom view of the reservoir subassembly of thedevice 300 of FIG. 12.

FIGS. 23 and 24 are detailed views of the reservoir subassembly 325 andvalve subassembly (i.e., valve spool 326 and valve seat 328) of thedevice 300 of FIG. 12 in a closed and open position, respectively.Specifically, the spool 326 includes a number of raised detents 332which, when in the closed position as in FIG. 23, block a fluid path 333between a reservoir path 330 and a patient needle path 331. When thespool 326 is pushed inward into the valve seat 328, the raised detentsare moved clear of the fluid path allowing the contents of the reservoirto travel from the reservoir path 330 to the needle path 331 via path333.

As with the first embodiment of the present invention 100 in FIG. 1, thesecond embodiment of the present invention 300 can be constructed toprovide a patch-like, wearable, self-contained substance infusion devicethat can be used to deliver a variety of medications to a patient. Thedevice 300, provides a hidden patient needle or needles 340 prior to andduring use, and can be secured to a patient via an adhesive surface (notshown) disposed on the lower housing 350. The pressurization of thecontents of the reservoir (i.e., contents contained between thereservoir film 320 and the reservoir subassembly 325) can be achieved byremoving or displacing the spring retention disk 310, as describedabove, to pressurize the contents, and the device can then be furtheractivated via a reasonable force applied to the top push surface of theupper housing 305 to seat the patient needles 340. In doing so, thedevice 300 facilitates self-injection and reduces or eliminatesvariations in injection techniques between users.

In a third embodiment of the device, shown in FIGS. 25 through 27, apush-button design 400 is shown wherein the activation and energizing ofthe device is also accomplished in a single multi-function/step process.FIG. 25 is an exploded view of the third embodiment of a patch-likeinjector or infusor system. FIGS. 26 and 27 are cross-sectional views ofthe third embodiment of the patch-like injector or infusor system ofFIG. 25 prior to, and subsequent to activation.

In the third embodiment of the present invention shown in FIGS. 25through 27, an infusion device 400 includes a push button 405, areservoir subassembly 410, a Belleville spring retention handle 430, atleast one Belleville spring 435, a reservoir film 440, a reservoir firmsurface 442, a T pin 445, at least one patient microneedle 460, and alower housing 470. The T pin 445 further includes a valve assembly 450,and the lower housing 470 can include an adhesive surface 475.

As shown in FIGS. 25 through 27, the embodiment of the present invention400 can be constructed to provide a patch-like, wearable, self-containedsubstance infusion device that can be used to deliver a variety ofmedications to a patient. The device 400, provides the hidden patientneedle or needles 460 prior to and during use, and can be secured to apatient via the adhesive surface 475. The pressurization of the contentsof the reservoir (i.e., contents provided between the reservoir film 440and the reservoir firm surface 442), can be achieved by removing ordisplacing the spring retention handle 430, thereby releasing theBelleville spring 435 to pressurize the reservoir contents. The devicecan then be further activated by slidably engaging the push button 405inward towards the device. As the push button 405 travels, a steppedopening 406 in the button 405 releases a right angle member 446 of the Tpin 445, thereby releasing the T pin 445 and allowing the patientneedles 460 to drop as driven forward by a coil spring 408 disposed in acircular opening 410 within the T pin 445. In doing so, the patientmicroneedles 460 seat. As the T pin 445 drops, the opening 451 of valve450 aligns with a fluid channel 452 in fluid communication with thereservoir, thereby creating a fluid path between the reservoir contentsand the patient needles 460.

FIGS. 26 and 27 are cross-sectional views of the device 400 prior to,and subsequent to activation. In FIG. 26 (shown without the springretention handle 430, lower housing 470, and the adhesive surface 475for simplicity), the T pin 445 is held up by the stepped opening 406,compressing the spring 408. Once the spring retention handle 430 isremoved releasing the Belleville spring 435, the device 400 can beplaced in position on the skin surface (not shown). As the button 405 ispushed, the stepped surface 406 releases the right angle member 446 ofthe T pin 445, thereby releasing the T pin 445 and allowing the patientneedles 460 to drop as shown in FIG. 27. In FIG. 27, the patientmicroneedles 460 seat and the opening 451 of valve 450 aligns with thefluid channel 452 in fluid communication with the reservoir, therebycreating a fluid path between the reservoir contents and the patientneedles 460.

In a fourth embodiment of the device shown in FIGS. 28 through 31, apush-button design 500 is shown wherein the activation and energizing ofthe device is also accomplished in a single multi-function/step process.FIGS. 28 through 31 are top views of the fourth embodiment of apatch-like injector or infusor system. FIGS. 32 and 33 are partialcross-sectional views of a valve subassembly of the patch-like injectoror infusor system of FIG. 28 in a closed and open position,respectively.

As shown in FIGS. 28 through 31, the device includes a button 505, aspring 510, a manifold arm 520, an activation ring 530, a pop opener540, a reservoir 550, a valve assembly 560 and a valve engagement detent570. The spring 510 has a first and second tab 521 and 522, at oppositesides respectively, and is secured within the device 500 to exert adownward force via the first tab when the second tab is raised, and toexert a downward force via the second tab when the first tab is raised,the force being exerted upon the ring 530 component (i.e., 511, 513,514) or the manifold component (i.e., 520) beneath the respective tab. ABelleville spring (not shown) is also provided beneath the reservoir550. A cover (not shown) is also provided to cover the above componentsbut omitted here for illustration purposes. The device of FIG. 28 isconfigured to operate between a loaded position, as shown in FIG. 28, anactivated, or fired position, shown in FIGS. 29 and 30, and a retractedposition shown in FIG. 31.

Specifically, as shown in FIG. 28, after application of the patch-likedevice 500 upon a skin surface (not shown) substantially as describedabove, a force applied to the push button 505 will cause the push button505 to pivot, or flex about point 506. As the button 505 pivots, thelinear member 508 of the push button 505 contacts the activation ring530 at a first detent 509, rotating the ring 530 as shown by the arrowA. As the ring 530 rotates, the spring 510 drops from a perch 511 into agroove 512 and drives the manifold and manifold arm 520 downwards. Also,as the ring 530 rotates, the pop opener 540 is engaged by an incline 582(see FIGS. 35 and 36) on the ring 530 which serves to disengage the popopener 540 from the Belleville spring, releasing the Belleville springand thereby pressurizing the reservoir 550 contents. Once the pushbutton 505 is released a first time, the linear member 508 of the pushbutton 505 is retracted by the spring force of the pivot point 506,releasing the first activation ring 530 first detent 509, and seatingbehind a second activation ring detent 516, shown in FIG. 30. In doingso, pushing the push button 505 a second time rotates the activationring 530 further, releasing the opposite tab 521 of the spring 510 intoopening 517, and diving the previously lower spring tab 522 up anincline and upon perch 513, allowing the manifold arm 520 to rise andretract the patient needles 541 as shown in FIG. 31.

In addition to the above, the push button 505 also engages the valveassembly 560 via a detent 570. The valve, shown and described in greaterdetail with reference to FIGS. 32 and 33, is pushed into an openposition allowing fluid communication as provided by a continuous path561, between the valve 560 and through the manifold arm 520. As shown inFIGS. 32 and 33, the valve assembly 560 includes a soft plastic member572 extending between a contact surface 562 and an enlarged proximal end571 disposed within a rubber seal 564 when in a closed position. Thevalve assembly 560 can be constructed within the manifold arm 520 (i.e.,within a molded coupling between the manifold arm 520 and the reservoir550) to provide a continuous fluid communication path within the singlereservoir assembly.

Specifically, as shown in FIG. 32, the push valve assembly 560 includesa soft member 572 slidably engaged within a rubber seal 564 in fluidcommunication with the reservoir 550. The valve assembly 560 has as aninitial state and an activated state, and includes a large diameterdistal end having a distal set of radially projecting fins, or ribs 573,and a reduced diameter body extending to an enlarged proximal end 571.In the initial state, the valve 560 distal ribs 573 serve to preventmicrobial ingress into the fluid path 574, and the enlarged proximal end571 creates a seal to trap the drug safely within the reservoir 550.Both sets of ribs 573 and end 571 are performing critical tasks inpreventing fluid loss from inside the reservoir over long periods oftime as well as preventing contamination of the drug from outside thereservoir over the same period of time.

In use, the member 572 will eventually be pushed into an activated stateby the movement of the push button 505, and contact between the detent570 and the contact surface 562. As shown in FIG. 33, the movement ofthe member 572 advances the enlarged proximal end 571 from an engagementposition with the rubber seal 564, which permits the drug to flow fromthe reservoir 550, past the enlarged proximal end 571 and into the valvefluid path 574. At the same time, the distal set of ribs 573 are bynature also pushed in and the location of the ribs 573 themselvestranslate into a position such that they direct the fluid from thereservoir 550, through the valve fluid path 574, and down the fluid path561 to the patient needle manifold (not shown).

In a second version of the fourth embodiment shown in FIGS. 34, 35 and36, alternate spring and valve versions can be used in place of thestamped metal flat spring 510 and valve assembly 560 of FIGS. 28 through31. In FIGS. 34 and 35, a spring 581 is shown having a substantiallycircular cross-section and coiled above the reservoir 550 and manifoldarm 520. Additionally, any number of valve assemblies 584, such as thosedescribed in greater detail below, can be provided in place of the pushtype valve assembly 560 of FIG. 28. In addition, a combination ofactivation ring and spring can be used in the other embodimentsdescribed above. In doing so, the benefits of an activation ring formultiple push button functions can be provided.

FIGS. 35 and 36 are further provided to show the pop opener 540 whichengages an incline 582 as the ring 530 is turned, which serves todisengage the pop opener 540 from the Belleville spring (not shown),releasing the Belleville spring and thereby pressurizing the reservoir550 contents. In FIG. 36, a second version of the Pop opener 583 isshown, which engages the incline 582 substantially as described above.

In a fifth embodiment of the device, shown in FIGS. 37 through 41, apush-button design 700 is shown wherein the activation and energizing ofthe device is also accomplished in a single multi-function/step process.FIGS. 37 through 41 are cross-sectional views of the fifth embodiment ofa patch-like injector or infusor system. FIGS. 42 through 44 arecross-sectional views of the reservoir subassembly of the patch-likeinjector or infusor system of FIG. 37. FIGS. 46 through 48 arecross-sectional views of a valve subassembly of the patch-like injectoror infusor system of FIG. 37 in closed and open positions, and FIG. 49is a view of a two-shot patient needle manifold subassembly of thepatch-like injector or infusor system of FIG. 37. FIGS. 50 through 54are views of example assembly steps of the patch-like injector orinfusor system of FIG. 37.

In the fifth embodiment of the present invention, an infusion device 700includes an upper housing 705, reservoir 710, a Belleville springretention handle 730, at least one Belleville spring 735, a reservoirfilm 740, a patient needle manifold 745, at least one patientmicroneedle 760, and a lower housing 770. The reservoir 710 is shown ingreater detail in FIGS. 42 through 44, and further includes an outercircumference arm 711 having a fluid communication path 713 extendingfrom the valve assembly 750 to the manifold 745. The reservoir 710further includes a rigid portion 712 disposed opposite the film 740,capturing a substance therebetween and placing it in fluid communicationwith the valve assembly 750. The manifold 745 can incorporate adissimilar material dovetail bonding 746 described in greater detailbelow with reference to FIG. 101. The device further includes a valveassembly 750 adjacent to a push button 780. The valve assembly 750 isshown in greater detail in FIGS. 45 through 46. Finally, an improvedsafety assembly is provided to activate and shield the microneedlesafter use, and is described and shown in greater detail below.

As shown in FIGS. 37 through 41, the embodiment of the present invention700 can be constructed to provide a patch-like, wearable, self-containedsubstance infusion device that can be used to deliver a variety ofmedications to a patient. The device 700, provides a hidden patientneedle or needles 760 prior to and during use, and can be secured to apatient via an adhesive surface (not shown) disposed on the lowerhousing 770. The activation of the device 700 following proper placementcan be achieved through a simple motion of the push button 780.Specifically, the slidable engagement of the push button 780 serves torelease the Belleville spring 735, thereby pressurizing the contents ofthe reservoir 710. The push button 780 engagement further serves to opena valve assembly 750, establishing a continuous fluid communication pathbetween the reservoir 710 contents and the patient microneedles 760.Finally, the push button 780 engagement serves to release a supportmember (not shown) from the patient needle manifold 745, allowing thepatient needles 760 to seat and completing device activation. Inachieving the above functions, the push button 780 engagement furtherserves to release a safety assembly described in greater detail below,thereby reducing the risk of sticks by the patient needles 760. Asignificant benefit of the embodiment described above includes theability to achieve each of these functions in a single push buttonaction. Additionally, another significant benefit includes the use of acontinuous fluid communication path comprised of the reservoirsubassembly.

Returning to FIG. 37, once the device 700 is properly positionedsubstantially as described above, the device 700 is activated by slidingthe push button 780 inward towards the device. This slidable engagementdrives an incline 782 towards the retention handle 730. As the incline782 and retention handle 730 engage, the retention handle 730 isdisplaced from a position securing the Belleville spring 735, allowingthe spring 735 to pressurize the reservoir 710. Specifically, this stepreleases the Belleville spring 735 allowing it to press against theflexible film 740 of the reservoir 710, pressurizing the reservoircontents between the film 740 and the rigid portion 712. This activationstep also serves to displace a support from beneath manifold 745,releasing the patient needle manifold 745 which is urged downward by thecompression of the outer circumference arm 711 (or any number of springsas described above) and seating the patient needles 760. As furthershown in FIGS. 42 through 45, the outer circumference arm 711 can alsoextend about the opposite side of the reservoir 710 to provide asubstantially continuous outer circumference arm that can act as aneedle stabilizer, extending from the valve assembly 750 to the manifold745. As shown in FIG. 42, the needle stabilizer can be provided about anarcuate path around the periphery of the reservoir, opposite to theneedle conduit comprised of the outer circumference arm 711 and fluidpath 713 therein, to stabilize the needles when the outer circumferencearm 711 is used as the downward urging spring. Finally, the activationstep also serves to open the valve assembly 750, establishing a fluidcommunication path between the reservoir 710 and the patient needles760.

Specifically, as shown in cross-sectional views FIGS. 45, 46 and 47, thevalve assembly 750 includes a plastic button 751 slidably engaged withina rubber stopper 752 in fluid communication with the reservoir 710. Thatis, for fluid communication the released contents of the reservoir firstleave the containment of the reservoir, and are directed to then travelto the needle. The valve assembly 750 has as an initial state and anactivated state, and includes a large diameter distal end having adistal set of radially projecting fins, or ribs 753 forming a body seal,and a reduced diameter proximal end having a proximal set of detents 754forming a reservoir seal. As shown in FIG. 47, the reservoir seal ofdetents 754 is within the fluid flow path, whereas only one side, theinner side, of the body seal is ever in contact with the fluid flowpath. The outer side of the body seal of ribs 753 facing the button 751are never in contact with the fluid flow path. In use, the button 751will eventually be pushed into an activated state by the movement of thepush button 780 and the set of detents 754 will be advanced fromengagement with the rubber stopper 752, which permits the drug to flowfrom the reservoir 710, past the detents 754 and into the fluid path713. As stated above, a significant benefit to each embodiment describedabove includes the ability to achieve each step in a single push buttonaction. Additionally, another significant benefit includes the use of acontinuous fluid communication path comprised of the reservoirsubassembly.

A series of assembly FIGS. 50 through 54 show an example assemblyprocess for the above device. In FIG. 50, the lower housing 770, securedBelleville spring 730, and a push button 780 are prepared to receive thereservoir and upper housing. In FIG. 51, the reservoir 710, and manifold745 (including an optional needle cap 719) are prepared to drop into thelower housing 770. In FIG. 53, the upper housing 705 is then prepared todrop onto the lower housing 770.

In each embodiment described above, the reservoir (i.e., 150 of FIG. 4)of the infusion device can be comprised of a rigid portion (i.e., 152 ofFIG. 4) used in conjunction with one or more non-distensible butflexible films (i.e., 151 of FIG. 4), such as metallized films, and cancontain any number of substances between either a first and second film,where either the first or second film is also positioned against therigid portion, or between a first film and the rigid portion. The rigidportion, or reservoir base, can be comprised of and serve as a hardportion of the reservoir against which the flexible film can be pressed.The rigid portion can contain a dished out central section and a flange,provided about the perimeter of the rigid portion to allow for heatsealing the flexible film, or film lid to the rigid portion and forminga content reservoir, or chamber, therebetween. As at least one wall ofthe chamber comprises a flexible film and at least one wall of thechamber comprises a rigid surface, one or more Belleville springs (i.e.,130 of FIG. 4) can be placed adjacent to the flexible film and used toapply a substantially constant pressure to the flexible film, andpressurize the reservoir chamber and contents.

The Belleville spring, which can be further provided having a springfollower as described in greater detail below, is provided to apply asubstantially even and constant pressure to the flexible film of thereservoir, compressing the contents of the reservoir between theflexible film and the rigid portion, and forcing the contents from thereservoir through one or more flow paths via a valve assembly (i.e., 120of FIG. 1) where desired. As noted above, the reservoir can also be madeup of two or more flexible, non-distensible films, wherein the contentscan be contained between the films and at least one film is attached tothe rigid portion to provide a rigid base for compressing andpressurizing the contents of the reservoir. In yet another embodiment ofthe reservoir subassembly, the flow rate is automatically adjusted froman initial high rate to one or more stepped-down lower flow rates.Additional details of an adjusting flow rate are further discussed in aU.S. patent application of Jim Fentress et al., Ser. No. 10/396,719,filed Mar. 26, 2003, entitled “Multi-Stage Fluid Delivery Device AndMethod”, the entire content of which is incorporated herein byreference.

The flexible film of the reservoir subassembly (i.e., element 151 ofFIG. 4) can be made of non-distensible materials or laminates, such asmetal-coated films or other similar substances. For example, onepossible flexible laminate film which can be used in the reservoir ofthe first embodiment (i.e., element 151 of FIG. 4) can be comprised of afirst polyethylene layer, a second chemical layer as known to thoseskilled in the art to provide an attachment mechanism for a third metallayer which is chosen based upon barrier characteristics, and followedby a fourth layer comprised of either polyester or nylon. By utilizing ametal-coated or metallized film in conjunction with a rigid portion, thebarrier properties of the reservoir are improved, thereby increasing orimproving the shelf life of the contents contained within. For example,where a reservoir content includes insulin, the primary materials ofcontact in the reservoir of the embodiments described above includelinear, low-density polyethylene (LLDPE), low-density polyethylene(LDPE), cyclic olefin copolymer (COC) and Teflon. As described ingreater detail below, the primary materials of contact in the remainingflow path of the reservoir contents include polyethylene (PE), medicalgrade acrylic, and stainless steel. Such materials which are in extendedcontact with the contents of the reservoir preferably pass ISO 10-993and other applicable biocompatibility testing.

The reservoir is further preferably able to be stored for the prescribedshelf life of the reservoir contents in applicable controlledenvironments without adverse effect to the contents and is capable ofapplications in a variety of environmental conditions. Additionally, thebarrier provided by the components of the reservoir do not permit thetransport of gas, liquid and solid materials into or out of the contentsat a rate greater than that allowable to meet the desired shelf life. Inthe embodiments shown above, the reservoir materials are capable ofbeing stored and operated in a temperature range of approximately 34 to120 degrees F., and can have a shelf life of two or more years.

In addition to satisfying stability requirements, the reservoir canfurther ensure operation by successfully passing any number of leaktests, such as holding a 30 psi sample for 20 minutes without leaking.Additional filling, storage and delivery benefits resulting from theconfiguration of the reservoir include minimized headspace andadaptability as described in greater detail below.

The reservoir is preferably evacuated prior to filling, as described ingreater detail below. By evacuating the reservoir prior to filling, andhaving only a slight depression in the hard floor of the rigid portion,headspace and excess waste within the reservoir can be minimized. Inaddition, the shape of the reservoir can be configured to adapt to thetype of energizing mechanism used, e.g., a disk or Belleville springhaving any number of diameter and height dimensions. Additionally, usingan evacuated flexible reservoir during filling minimizes any air orbubbles within the filled reservoir. The use of a flexible reservoir isalso very beneficial when the device is subjected to external pressureor temperature variations, which can lead to increased internalreservoir pressures. In such case, the flexible reservoir expands andcontracts with the contents, thereby preventing possible leaks due toexpansion and contraction forces.

Yet another feature of the reservoir includes the ability to permitautomated particulate inspection at the time of fill, or by a user atthe time of use. One or more reservoir barriers, such as the rigidportion, can be molded of a transparent, clear plastic material, whichallows inspection of the substance contained within the reservoir. Thetransparent, clear plastic material is preferably a cyclic olefincopolymer that is characterized by high transparency and clarity, lowextractables and biocompatibility with the substance contained in thereservoir. In such applications, the reservoir includes minimal featureswhich could possibly obstruct inspection (i.e. rotation duringinspection is permitted).

A fluid path between the reservoir (i.e., 150 of FIG. 4) and the patientmicroneedles (i.e., 141 in FIG. 1) in the embodiments described above isconstructed of materials similar or identical to those described abovefor the reservoir, and that satisfy numerous biocompatibility andstorage tests. For example, as shown in Table 1 below, where a devicecontent includes insulin, the primary materials of contact in thereservoir of the embodiments include linear, low-density polyethylene,cyclic olefin copolymer and Teflon, and can also include a transparent,clear plastic. The primary materials of contact in the remaining flowpath between the reservoir and the microneedles of the patient needlemanifold include polyethylene, medical grade acrylic, and/or stainlesssteel.

TABLE 1 Path Component Material Reservoir Polyethylene, cyclic olefincopolymer and/or Teflon Reservoir Film Metal-coated film, such aspolyethylene, aluminum, polyester and/or nylon with a chemical tielayer, such as the product such as the product A83, manufactured byBeacon Converters of Saddle Brook N.J. Patient Needle ManifoldPolyethylene and/or medical grade acrylic Patient Needle Stainless steel

Specifically, the patient needles (i.e., 141 of FIG. 1) can beconstructed of stainless steel, and the patient needle manifold (i.e.140 of FIG. 1) can be constructed of polyethylene and/or medical gradeacrylic. Such materials when in extended contact with the contents ofthe reservoir preferably pass ISO 10-993 biocompatibility testing.

As shown in each embodiment above, a disk or Belleville spring (i.e.,130 of FIG. 1) is included in the devices for applying an essentiallyeven, constant force to the reservoir to force the contents from thereservoir, and is hereinafter sometimes referred to as a constant forcespring. The constant force spring is used to store energy that, whenreleased by device energizing, pressurizes the reservoir at the time ofuse. The Belleville spring is held in a flexed state by a retentiondisk, or handle (i.e., 135 in FIG. 1), that is positioned at the centerof a plurality of spring fingers. In doing so, the Belleville spring isprevented from putting stress on the film (i.e., 151 of FIG. 4) of thereservoir or any remaining device components during storage. Theretaining disk is sufficiently rigid to resist spring tension anddeformation, and should not fail under normal tensile load.

When the retention disk is pulled free of the Belleville spring, thefingers of the spring drop, and in doing so, exert a force on the filmlid of the reservoir. The edge of the Belleville spring is trapped aboutan outer circumference of the reservoir. The Belleville spring can beconfigured to preferably create a pressure within the reservoir of fromabout 1 to 50 psi, and more preferably from about 2 to about 25 psi, andmost preferably from about 15 to about 20 psi for intradermal deliveryof the reservoir contents. For sub-cutaneous injection or infusion, arange of about 2 to 5 psi may be sufficient. The Belleville spring canbe sized between about 1.15 to 1.50 inches in diameter, preferably 1.26inches, and further include a spring follower to allow for a full 600 μldelivery.

FIGS. 55 through 60 illustrate examples of various versions of aBelleville spring follower 800(a) through 800(c) which can each be usedin association with a Belleville spring 802 in the embodiments describedabove. In each version, a displacement member 800 is provided adjacentto the Belleville spring 802, such that as the Belleville spring 802travels between a flexed and relaxed position (i.e. is released by aretention member), the spring 802 exerts a substantially constant forceupon the displacement member, or follower 800, rather than directly uponthe flexible film (i.e., 151 of FIG. 4) of the reservoir. The follower800 in turn applies a more evenly distributed force to the reservoirfilm 804.

For example, as shown in Figure pairs 55 and 56, 57 and 58, and 59 and60, which illustrate a flexed and released Belleville spring 802position, respectively, the example followers 800(a), 800(b) and 800(c)conform to a shape of the rigid reservoir wall 806(a), 806(b), and806(c). Therefore, when the Belleville spring 802 is released as shownin FIGS. 56, 58 and 60, the Belleville spring 802 forces the followers800(a), 800(b) and 800(c) tightly against the rigid reservoir wall806(a), 806(b), and 806(c) respectively, minimizing dead space losses.An overmolded Belleville spring, as described in greater detail belowwith reference to FIGS. 90 through 92, can also be provided to furtherminimize such losses.

Each embodiment described above also contains at least one patientneedle, or microneedle (i.e., 141 of FIG. 1), but may contain several,such as the three microneedles. Each microneedle is preferably at least31 gauge or smaller, such as 34 gauge, and is anchored within a patientneedle manifold (i.e., 140 of FIG. 1) which can be placed in fluidcommunication with the reservoir. The microneedles, when more than oneis included in the device, can also be of differing lengths, or gauges,or a combination of both differing lengths and gauges, and can containone or more ports along a body length, preferably located near the tipof the needle or near the tip bevel if the needle has one.

In the embodiments described above, the use of multiple 34 gauge needlesto deliver the reservoir contents is practical as the infusion occursover a longer period than typically associated with an immediate syringeinjection requiring a much larger cannula, or needle. In the disclosedembodiments, any microneedles can be used which target either anintradermal or subcutaneous space, however, the embodiments shown aboveinclude intradermal microneedles of between 1 and 4 mm in length (i.e.,2 mm), and the arrangement of these patient needles can be in a linearor nonlinear array, and can include any number of needles as required bythe specific application.

The patient needles are positioned in a patient needle manifold. In thepatient needle manifold of each embodiment described above (i.e., 140 ofFIG. 1), at least one fluid communication path, or feed channel, isprovided to each patient needle. The manifold may simply have a singlepath to one or more patient needles, or may provide multiple fluid pathsor channels routing contents to each needle separately. These paths orchannels may further comprise a tortuous path for the contents totravel, thereby affecting fluid pressures and rates of delivery, andacting as a flow restrictor. The channels or paths within the patientneedle manifold can range in width, depth and configuration dependingupon application, where channel widths are typically between about 0.015and 0.04 inch, preferably 0.02 inch, and are constructed to minimizedead space within the manifold.

The devices described above are suitable for use in administeringvarious substances, including medications and pharmaceutical agents, toa patient, and particularly to a human patient. As used herein, apharmaceutical agent includes a substance having biological activitythat can be delivered through the body membranes and surfaces, andparticularly the skin. Examples, listed in greater detail below, includeantibiotics, antiviral agents, analgesics, anesthetics, anorexics,antiarthritics, antidepressants, antihistamines, anti-inflammatoryagents, antineoplastic agents, vaccines, including DNA vaccines, and thelike. Other substances that can be delivered intradermally orsubcutaneously to a patient include human growth hormone, insulin,proteins, peptides and fragments thereof The proteins and peptides canbe naturally occurring, synthesized or recombinantly produced.Additionally, the device can be used in cell therapy, as duringintradermal infusion of dendritic cells. Still other substances whichcan be delivered in accordance with the method of the present inventioncan be selected from the group consisting of drugs, vaccines and thelike used in the prevention, diagnosis, alleviation, treatment, or cureof disease, with the drugs including Alpha-1 anti-trypsin,Anti-Angiogenesis agents, Antisense, butorphanol, Calcitonin andanalogs, Ceredase, COX-II inhibitors, dermatological agents,dihydroergotamine, Dopamine agonists and antagonists, Enkephalins andother opioid peptides, Epidermal growth factors, Erythropoietin andanalogs, Follicle stimulating hormone, G-CSF, Glucagon, GM-CSF,granisetron, Growth hormone and analogs (including growth hormonereleasing hormone), Growth hormone antagonists, Hirudin and Hirudinanalogs such as hirulog, IgE suppressors, Insulin, insulinotropin andanalogs, Insulin-like growth factors, Interferons, Interleukins,Leutenizing hormone, Leutenizing hormone releasing hormone and analogs,Low molecular weight heparin, M-CSF, metoclopramide, Midazolam,Monoclonal antibodies, Narcotic analgesics, nicotine, Non-steroidanti-inflammatory agents, Oligosaccharides, ondansetron, Parathyroidhormone and analogs, Parathyroid hormone antagonists, Prostaglandinantagonists, Prostaglandins, Recombinant soluble receptors, scopolamine,Serotonin agonists and antagonists, Sildenafil, Terbutaline,Thrombolytics, Tissue plasminogen activators, TNF-, and TNF-antagonist,the vaccines, with or without carriers/adjuvants, includingprophylactics and therapeutic antigens (including but not limited tosubunit protein, peptide and polysaccharide, polysaccharide conjugates,toxoids, genetic based vaccines, live attenuated, reassortant,inactivated, whole cells, viral and bacterial vectors) in connectionwith, addiction, arthritis, cholera, cocaine addiction, diphtheria,tetanus, HIB, Lyme disease, meningococcus, measles, mumps, rubella,varicella, yellow fever, Respiratory syncytial virus, tick bornejapanese encephalitis, pneumococcus, streptococcus, typhoid, influenza,hepatitis, including hepatitis A, B, C and E, otitis media, rabies,polio, HIV, parainfluenza, rotavirus, Epstein Barr Virus, CMV,chlamydia, non-typeable haemophilus, moraxella catarrhalis, humanpapilloma virus, tuberculosis including BCG, gonorrhoea, asthma,atheroschlerosis malaria, E-coli, Alzheimers, H. Pylori, salmonella,diabetes, cancer, herpes simplex, human papilloma and the like othersubstances including all of the major therapeutics such as agents forthe common cold, Anti-addiction, anti-allergy, anti-emetics,anti-obesity, antiosteoporeteic, anti-infectives, analgesics,anesthetics, anorexics, antiarthritics, antiasthmatic agents,anticonvulsants, anti-depressants, antidiabetic agents, antihistamines,anti-inflammatory agents, antimigraine preparations, antimotion sicknesspreparations, antinauseants, antineoplastics, antiparkinsonism drugs,antipruritics, antipsychotics, antipyretics, anticholinergics,benzodiazepine antagonists, vasodilators, including general, coronary,peripheral and cerebral, bone stimulating agents, central nervous systemstimulants, hormones, hypnotics, immunosuppressives, muscle relaxants,parasympatholytics, parasympathomimetrics, prostaglandins, proteins,peptides, polypeptides and other macromolecules, psychostimulants,sedatives, sexual hypofunction and tranquilizers and major diagnosticssuch as tuberculin and other hypersensitivity agents as described inU.S. Pat. No. 6,569,143, entitled “Method of Intradermally InjectingSubstances”, the entire content of which is expressly incorporatedherein by reference.

Vaccine formulations which can be delivered in accordance with thesystem and method of the present invention can be selected from thegroup consisting of an antigen or antigenic composition capable ofeliciting an immune response against a human pathogen, which antigen orantigenic composition is derived from HIV-1, (such as tat, nef, gp120 orgp160), human herpes viruses (HSV), such as gD or derivatives thereof orImmediate Early protein such as ICP27 from HSVI or HSV2, cytomegalovirus(CMV (esp Human) (such as gB or derivatives thereof), Rotavirus(including live-attenuated viruses), Epstein Barr virus (such as gp350or derivatives thereof), Varicella Zoster Virus (VZV, such as gpl, IIand IE63) or from a hepatitis virus such as hepatitis B virus (forexample Hepatitis B Surface antigen or a derivative thereof), hepatitisA virus (HAV), hepatitis C virus and hepatitis E virus, or from otherviral pathogens, such as paramyxoviruses: Respiratory Syncytial virus(RSV, such as F and G proteins or derivatives thereof), parainfluenzavirus, measles virus, mumps virus, human papilloma viruses (HPV forexample HPV6, 11, 16, 18), flaviviruses (e.g. Yellow Fever Virus, DengueVirus, Tick-borne encephalitis virus, Japanese Encephalitis Virus) orInfluenza virus (whole live or inactivated virus, split influenza virus,grown in eggs or MDCK cells, or whole flu virosomes or purified orrecombinant proteins thereof, such as HA, NP, NA, or M proteins, orcombinations thereof), or derived from bacterial pathogens such asNeisseria spp, including N. gonorrhea and N. meningitidis (for examplecapsular polysaccharides and conjugates thereof, transferrin-bindingproteins, lactoferrin binding proteins, Pi1C, adhesins); S. pyogenes(for example M proteins or fragments thereof, C5A protease, lipoteichoicacids), S. agalactiae, S. mutans; H. ducreyi; Moraxella spp, including Mcatarrhalis, also known as Branhamella catarrhalis (for example high andlow molecular weight adhesins and invasins); Bordetella spp, includingB. pertussis (for example pertactin, pertussis toxin or derivativesthereof, filamenteous hemagglutinin, adenylate cyclase, fimbriae), B.parapertussis and B. bronchiseptica; Mycobacterium spp., including M.tuberculosis (for example ESAT6, Antigen 85A, -B or -C), M. bovis, M.leprae, M. avium, M. paratuberculosis M. smegmatis; Legionella spp,including L. pneumophila; Escherichia spp, including enterotoxic E. coli(for example colonization factors, heat-labile toxin or derivativesthereof, heat-stable toxin or derivatives thereof), enterohemorragic E.coli, enteropathogenic E. coli (for example shiga toxin-like toxin orderivatives thereof); Vibrio spp, including V. cholera (for examplecholera toxin or derivatives thereof); Shigella spp, including S.sonnei, S. dysenteriae, S. flexnerii; Yersinia spp, including Y.enterocolitica (for example a Yop protein), Y. pestis, Y.pseudotuberculosis; Campylobacter spp, including C. jejuni (for exampletoxins, adhesins and invasins) and C. coli; Salmonella spp, including S.typhi, S. paratyphi, S. choleraesuis, S. enteritidis; Listeria spp.,including L. monocytogenes; Helicobacter spp, including H. pylori (forexample urease, catalase, vacuolating toxin); Pseudomonas spp, includingP. aeruginosa; Staphylococcus spp., including S. aureus, S. Epidermidis;Enterococcus spp., including E. faecalis, E. faecium; Clostridium spp.,including C. tetani (for example tetanus toxin and derivative thereof),C. botulinum (for example Botulinum toxin and derivative thereof), C.difficile (for example clostridium toxins A or B and derivativesthereof); Bacillus spp., including B. anthracis (for example botulinumtoxin and derivatives thereof); Corynebacterium spp., including C.diphtheriae (for example diphtheria toxin and derivatives thereof);Borrelia spp., including B. Burgdorferi (for example OspA, OspC, DbpA,DbpB), B. garinii (for example OspA, OspC, DbpA, DbpB), B. afzelii (forexample OspA, OspC, DbpA, DbpB), B. andersonii (for example OspA, OspC,DbpA, DbpB), B. Hermsii; Ehrlichia spp., including E. equi and the agentof the Human Granulocytic Ehrlichiosis; Rickettsia spp, including R.rickettsii; Chlamydia spp., including C. Trachomatis (for example MOMP,heparin-binding proteins), C. pneumoniae (for example MOMP,heparin-binding proteins), C. psittaci; Leptospira spp., including L.interrogans; Treponema spp., including T. pallidum (for example the rareouter membrane proteins), T. denticola, T. hyodysenteriae; or derivedfrom parasites such as Plasmodium spp., including P. Falciparum;Toxoplasma spp., including T. gondii (for example SAG2, SAG3, Tg34);Entamoeba spp., including E. histolytica; Babesia spp., including B.microti; Trypanosoma spp., including T. cruzi; Giardia spp., includingG. lamblia; Leshmania spp., including L. major; Pneumocystis spp.,including P. Carinii; Trichomonas spp., including T. vaginalis;Schisostoma spp., including S. mansoni, or derived from yeast such asCandida spp., including C. albicans; Cryptococcus spp., including C.neoformans, as described in PCT Patent Publication No. WO 02/083214,entitled “Vaccine Delivery System”, the entire content of which isexpressly incorporated herein by reference.

These also include other preferred specific antigens for M.tuberculosis, for example Tb Ra12, Tb H9, Tb Ra35, Tb38-1, Erd 14, DPV,MTI, MSL, mTTC2 and hTCC1. Proteins for M. tuberculosis also includefusion proteins and variants thereof where at least two, preferablythree polypeptides of M. tuberculosis are fused into a larger protein.Preferred fusions include Ra12-TbH9-Ra35, Erd14-DPV-MTI, DPV-MTI-MSL,Erd14-DPV-MTI-MSL-mTCC2, Erd14-DPV-MTI-MSL, DPV-MTI-MSL-mTCC2,TbH9-DPV-MTI. Most preferred antigens for Chlamydia include for examplethe High Molecular Weight Protein (HWMP), ORF3, and putative membraneproteins (Pmps). Preferred bacterial vaccines comprise antigens derivedfrom Streptococcus spp, including S. pneumoniae (for example capsularpolysaccharides and conjugates thereof, PsaA, PspA, streptolysin,choline-binding proteins) and the protein antigen Pneumolysin (BiochemBiophys Acta, 1989, 67, 1007; Rubins et al., Microbial Pathogenesis,25,337-342), and mutant detoxified derivatives thereof. Other preferredbacterial vaccines comprise antigens derived from Haemophilus spp.,including H. influenzae type B (“Hib”, for example PRP and conjugatesthereof), non typeable H. influenzae, for example OMP26, high molecularweight adhesins, P5, P6, protein D and lipoprotein D, and fimbrin andfimbrin derived peptides or multiple copy variants or fusion proteinsthereof. Derivatives of Hepatitis B Surface antigen are well known inthe art and include, inter alia, PreS1, PreS2 S antigens. In onepreferred aspect the vaccine formulation of the invention comprises theHIV-1 antigen, gp120, especially when expressed in CHO cells. In afurther embodiment, the vaccine formulation of the invention comprisesgD2t as hereinabove defined.

In addition to the delivery of substances listed above, the device andmethod can also be used for withdrawing a substance from a patient, ormonitoring a level of a substance in the patient. Examples of substancesthat can be monitored or withdrawn include blood, interstitial fluid orplasma. The withdrawn substances can then be analyzed for analytes,glucose, drugs and the like.

The embodiments of the present invention described above preferablyinclude a push-surface (i.e. push button) design wherein the device canbe positioned and affixed to a skin surface, and energized and/oractivated by gently pressing a push button or push surface.Specifically, the user in a first step removes the device from a sterilepackaging and removes an adhesive cover (not shown) and/or a needle cap.Upon removal of the device from the package and prior to use, thefeatures described above allows the user to inspect both the device andthe contents therein, including inspection for missing or damagedcomponents, expiration dates(s), hazy or color-shifted drugs, and soforth. After use, the user can once again inspect the device to ensurethe entire dose was delivered. In this regard, the device can include anend-of-dose indicator, as described in greater detail below, or anadministered dose indicator for example, consisting of a readable gaugearea that is at least 20% of the surface area of the device housing andaccurate to within ±10% of the labeled dose.

The next step is the positioning and application of the device to theuser's skin surface. Like a patch, the user firmly presses the deviceonto the skin. The device includes a bottom surface having an adhesivelayer to secure the device to the skin of the user. This bottom surfacecan be flat, contoured, or shaped in any suitable fashion, and includesan adhesive layer thereon, which would most likely be covered prior toshipping. Prior to use, the user peels back the adhesive covering, suchas a film covering the adhesive, thereby exposing the adhesive forplacement against the skin.

Once removed, the user is then able to place the device against the skinand press to ensure proper adhesion. As noted above, once properlypositioned, the device is activated by sliding a button (i.e. 105 inFIG. 1) or pressing a push surface of a top housing (i.e., 305 of FIG.12). This activation step releases the Belleville spring allowing it topress against the flexible film of the reservoir, pressurizing thereservoir. This activation step also serves to release the patientneedle manifold and seat the patient needles. Finally, the activationstep also serves to open one or more valve assemblies or fluid paths asdescribed above, establishing a fluid communication path between thereservoir and the patient needles. A significant benefit to eachembodiment described above includes the ability to achieve each step ina single push action. Additionally, another significant benefit includesthe use of a continuous fluid communication path comprised entirelywithin the reservoir assembly.

Once activated, the user typically leaves the device in position, orwears the device, for some period of time, such as ten minutes toseventy-two hours for complete delivery of the device contents, and thenremoves and discards the device with no damage to the underlying tissue.However, upon intentional or accidental removal, one or more safetyfeatures can deploy as described in greater detail below to shield theexposed needles resulting from activation. The safety features howevercan be configured to not deploy if the button and button slide has notbeen pushed and the patient needles extended, preventing pre-use safetydeployment.

To prevent inadvertent or accidental needle sticks, intentional re-useof the device, and to shield exposed needles, a locking needle safetymechanism can be provided and activated automatically immediately uponremoval of the device from the skin surface. In a first version of asafety feature embodiment described in greater detail below, a flexiblesafety member can be provided which provides in part, an adhesivecovered, flat surface portion that is in contact with the patient'sskin. The member, once released, is held in position by the skinsurface. Once the device is removed from the skin surface, the memberextends to a position shielding the patient microneedles. The extendedsafety member is then locked into place and prevents accidental injuryor exposure to the patient needles. Still other versions of a safetyfeature embodiment include a flexible patient needle cap (i.e., 111 ofFIG. 1), which serves to protect the patient needles and provide asterile barrier. The needle cap can serve to protect the patient needlesduring device manufacture, protect the user prior to use, and provide asterility barrier at any point prior to removal. The needle cap can beattached via a press fit with the patient needle manifold.

In addition to the performance advantages described above, anotheradvantage of the embodiments described above is the ability to make twoor more distinct, self-contained subassemblies (i.e., a reservoirsubassembly and a body subassembly) that allow for assembly flexibility.Each subassembly is self contained and stable, and provides the abilityto separate the reservoir subassembly from remaining components,allowing separate filling and inspection of the reservoir, whilepreventing the unnecessary handling of the remaining components.Additionally, should any of the additional components be discarded, thecostly reservoir contents can be excluded. Also, the reservoirsubassembly contains no unnecessary parts and as a result, brings a lowparticle load into filling operations. Also, all stored energycomponents are in the body subassembly so they cannot be inadvertentlydeployed during filling of the reservoir. Specifically, no springs areincluded in the reservoir subassembly which prevents the chance ofunwanted spring release during filling. As noted, minimal extraneouscomponents in the reservoir subassembly reduce particle load, and onlycontain necessary components, such as the reservoir and lid. No danglingparts are present, and typically require only drop-in assembly steps.Additionally, the reservoir can be located on top of the device, whichcan allow full and unobscured view of the drug reservoir through atransparent component, allowing view of the reservoir contents to theuser or manufacturer.

Any number of the components provided in the above exemplary embodimentscan be provided having additional functions and features to betterachieve the desired results. Specifically, the use of improvedmaterials, valve and Belleville spring constructions, safeties andpackaging methods and materials, as described in greater detail below,can be provided with the exemplary embodiments to achieve the desiredresults. For example, returning to FIG. 1, the push button 105 engagesthe push valve 120, initiating flow between the now pressurizedreservoir 150 and the manifold assembly 140. The push/pull valveassembly 120 of the embodiment shown in FIG. 1 is constructed torestrict flow between the reservoir 150 and the patient needle manifold140 until pushed into an open position by the push button 105 and can becomprised of any number of improved valve assemblies as described ingreater detail below.

As shown in FIG. 61, an improved valve assembly 1200 can consist of apush/pull valve rod 1206 seated in an opening 1201 within a housing 1203in fluid communication with the reservoir (not shown) via path 1202.FIGS. 61 and 62 illustrate a pull valve 1200 and 1300 in a closedposition, and FIGS. 63 and 64 illustrate a push valve 1400 and 1500 in aclosed position.

Conventional valve assemblies typically include a plastic memberslidably engaged within a rubber stopper in fluid communication with thereservoir, and wherein the plastic member includes a proximal end seatedsecurely within the rubber stopper to prevent any fluid escaping thereservoir. As the plastic member is engaged and displaced within therubber stopper by a push button, an opening is created at the proximalend of the plastic member which allows fluid communication from thereservoir. However, such assemblies require a separate rubber plug orstopper, in which the proximal end of the plastic member is seated.

In FIGS. 61 through 63, valve embodiments 1200, 1300 and 1400 are shownwherein the valve body 1206, 1306 and 1406 are constructed of anelastomer. The valves and valve ribs 1207, 1307 and 1407 areconstructed, in part, of an elastomer which allows the elimination of aseparate rubber plug or seal (i.e. 224 of FIG. 6). Additionally, thevalves of FIGS. 62 and 63, have a linear measurement sufficient toprevent the ribs 1307 and 1407 from contacting the fluid path escapeopening 1304 and 1404, and possibly becoming damaged.

Specifically, in each of FIGS. 61 through 63, an opening 1202, 1302, and1402 is provided in fluid communication with the reservoir (not shown).A second opening 1204, 1304, and 1404 is provided in fluid communicationwith the patient needle manifold (not shown). As the valve body 1206,1306, and 1406 travels from a closed to open position, sealing members,or ribs 1207, 1307 and 1407, of the valve body 1206, 1306 and 1406,respectively, move to provide a fluid communication path betweenopenings 1202 and 1204, 1302 and 1304, and 1402 and 1404, respectively.However, such sealing members are not allowed to contact the openings,specifically openings 1204, 1304, and 1404 in such a manner as to allowthe opening's edges to act in an abrasive manner against the valve body1206, 1306, and 1406, or sealing members 1207, 1307 and 1407. This isprevented in each valve embodiment 1200, 1300, and 1400 by providing asufficient clearance between the sealing members 1207, 1307 and 1407 andthe openings 1204, 1304 and 1404 in either an open or closed valveposition. For example, the ribs 1307 of FIG. 62, are sufficiently placedto avoid contact with the openings 1304 when the valve is closed,opened, or in between. Still further improvements and descriptions ofthese sealing members are provided by the valve bodies as described ingreater detail below.

The valve assembly shown in FIGS. 64 through 68, further accomplishesthe complex task of low pressure fluid sealing, high pressure fluidsealing, and anti-microbial ingress restriction, all in one part. Thevalve embodiment 1500 entails two components, which together form afluid valve system. The first component is the valve plunger rod 1502,and the second component is the cylindrical body opening 1504 that thevalve plunger rod 1502 is housed within. The entire fluid valve systemis incorporated into a fluid reservoir such as might be used for holdingdrugs in liquid form within the infusion device 100 of FIG. 1.

The valve 1500 has as an initial state and an activated state, andincludes a proximal and distal set of radially projecting fins, or ribs1506 and 1508, respectively, as can be seen in FIGS. 64 through 68. Inthe initial state, the valve's proximal ribs 1506 create a seal to trapthe drug safely within the reservoir (not shown), while the distal ribs1508 serve to prevent microbial ingress into the fluid path 1510. Bothsets of ribs 1506 and 1508 are performing critical tasks in preventingfluid loss from inside the reservoir over long periods of time as wellas preventing contamination of the drug from outside the reservoir overthe same period of time.

In use, the valve plunger rod 1502 will eventually be pushed into anactivated state by the movement of the push button (not shown) and thefunctions of the ribs 1506 and 1508 change to accomplish new roles. Whenpushed in, the proximal set of ribs 1506 will be advanced into anenlarged cavity 1512 in fluid communication with the reservoir whichpermits the drug to flow from the reservoir, past the proximal ribs 1506and into the valve fluid path 1510. At the same time, the distal set ofribs 1508 are by nature also pushed in and the location of the ribs 1508themselves translate into a position such that they direct the fluidfrom the reservoir, through the valve fluid path 1510 out a side hole1514, and down the final fluid path (not shown) to the patient needles(not shown).

As they direct the fluid out the side hole 1514, the distal set of ribs1508 must now function as a high pressure seal to ensure the fluidcorrectly exits the appropriate side hole 1514, rather than escape pastthe distal ribs 1508 themselves, whereby the fluid would be lost. Toensure this is successfully achieved, the valve assembly can furtherincorporate a slightly tapered cylindrical valve body opening 1504 inwhich the valve plunger rod 1502 travels as shown in FIGS. 65 through68. This tapered body opening 1504 permits the distal ribs 1508 whichform the fluid seal, to safely “take a set” when in an initial, orclosed state as shown in FIGS. 65 through 67. That is, the ribs 1508 ofthe plunger rod 1502 typically will relax over time within the insidediameter of the cylindrical valve body opening 1504 when in a closedposition. Therefore, over time the ribs 1508 will lose some ability toexert a desired radial pressure on the body when finally moved into anopen position.

When the distal ribs 1508 are acting as microbial ingress barriers asshown by arrow A in FIG. 67, this reduced radial pressure is permissibleand the valve will still function completely. However when the distalribs 1508 are translated forward as shown in FIG. 68 and their primaryfunction turns into that of high pressure seal against the flow of arrowB instead of microbial ingress barrier, the distal radial ribs 1508 arerequired to perform optimally as a fluid seal. Thus if the distal ribs1508 have “taken a set” when closed, they would be less effective toaccomplish this task when open if they are traveling in a non-taperedopening. Therefore, in the embodiment shown in FIGS. 65 through 68, aconically tapered body opening 1504 is further provided with theassembly 1500, therefore as the distal ribs 1508 move forward from theinitial state to the activated state, they will be “re-pressurized” dueto the reduced inside diameter provided by the conical tapered opening1504, and the distal ribs 1508 can then work effectively regardless of“taking a set” during the period when the valve 1500 was closed.

The advantage of having a conically tapered body opening 1504 is that itaccomplishes multiple sealing and fluid flow objectives with only asingle molded part. Typical valves for use in systems such as thisincorporate an elastomeric seal, or plug, in conjunction with a plungerrod to effect the same sealing characteristics that the embodiment shownin FIGS. 64 and 65 exemplifies. That is, in the embodiment shown inFIGS. 64 and 65, the seal or plug is eliminated, as the valve plungerrod 1502 used is comprised of a rigid portion, or member, and a softerovermold as described in greater detail below with reference to FIGS. 69and 72. Since the embodiments of FIGS. 69 and 72 accomplishes all therequired tasks with fewer parts, it exhibits significant cost savingsdue to reduced overall part counts, and provides for simplifiedmanufacturing and assembly processes.

One method of constructing such a valve plunger rod 1502 to eliminatethe need for an elastomer plug is with a one/two shot mold process asshown in FIGS. 69 through 74. In FIGS. 69, 70 and 71, a rigidpolyethylene member 1520 is constructed as a core member of the valve1502 and creates a rigid structure, and includes an enlarged distal end1521, a body 1522 to later support a number of distal fins, a reduceddiameter body 1523 to provided clearance for a flow path, and aminimally enlarged proximal end 1524 to later support a number ofproximal fins. FIG. 69 shows a perspective view of the core member 1520,FIG. 70 shows a side view of the core member 1520, and FIG. 71 shows across-sectional view of the core member 1520. In an exemplaryembodiment, the enlarged distal end 1521 has a diameter of approximately0.288 inches and a thickness of approximately 0.030 inches. The body1522 has a diameter of approximately 0.099 inches and a length ofapproximately 0.25 inches between end 1521 and body 1523. The reduceddiameter body has a diameter of approximately 0.040 inches and a lengthof approximately 0.023 inches between end 1524 and body 1522. Theenlarged proximal end 1524 has a diameter of approximately 0.10 inchesand a thickness of 0.01 inches and having a 45° tapered end extendingaxially therefrom.

In a second shot mold process shown in FIGS. 72, 73 and 74, an elastomerovermold 1530 is provided over the core member 1520 of FIGS. 69 through71. FIG. 72 shows a perspective view of the overmolded core member 1520,FIG. 73 shows a side view of the overmolded core member 1520, and FIG.74 shows a cross-sectional view of the overmolded core member 1520. Theresulting valve member, or valve plunger rod includes distal sealingfins 1531 and proximal sealing fin 1532, which provide a surface whichcan create a seal within the valve opening equal to those provided by aseparate plug. In doing so, the valve eliminates the need for a separaterubber plug or stopper in the valve. In an exemplary embodiment, theovermolded distal fins 1531 have a diameter of approximately 0.177inches and a thickness of approximately 0.016 inches. The overmoldedproximal fin 1532 has a diameter of approximately 0.114 inches and athickness of 0.02 inches and having a 45° tapered end extending axiallytherefrom.

The improved valve plunger rod and opening is only one improvedmechanism provided by the embodiments of the present invention. In yetanother improved valve embodiment, the infusion device can use arotating valve 1535 to provide fluid communication for an infusiondevice. FIG. 75 is a side view of a rotating valve, and FIG. 76 is across-sectional view of a rotating valve in a pre-use and in-useposition. The valve 1535 can have a simple valving alignment featurebetween paths 1536 and 1537, to permit fluid communication from areservoir (not shown) to a needle 1538 when the valve is rotated asindicated by arrow A. Still another rotating valve embodiment 1540 isshown in FIGS. 77, 78 and 79, with distinct fill, injection and closedpositions, or states. As shown in FIGS. 77 through 79, the rotatingvalve can include a first tube 1542 extending from arm 1548 androtatably fit within a second tube 1544, and having the infusion needles1546 attached to the first tube 1542 by a lever arm 1548. Each tubeincludes a number of openings for alignment to provide a fill position,a closed position, and an injection position, as described in greaterdetail below.

In a fill position, as shown in FIG. 79( a), a fill opening 1541 in thesecond tube 1544 is aligned with fill openings 1543 in the first tube1542, thereby in fluid communication with the reservoir via a reservoiropening 1554 in the second tube 1544. This allows fluid communicationbetween fill opening 1541 and the reservoir only. In an inject positionshown in FIG. 79( b), the fill openings 1543 in the first tube 1542 areblocked, and an injection opening 1552 in the first tube 1542 is alignedwith the reservoir opening 1554 in the second tube 1544. In a closedposition shown in FIG. 79( c), all openings of both the first and secondtubes are blocked.

When the device is armed and the valve is in the closed position asshown in FIG. 79( c), the fluid enters though the reservoir opening 1554in the side of the second tube 1544 but is stopped by the side wall ofthe first tube 1542. In this position, the needles 1546 are attached tothe first tube 1542 by a lever arm 1548, however, the fluid path betweenthe needles and the inside of the first tube is closed from the fluidpath of the second tube 1544, and the lever arm 1548 is positioned at anangle as to hold the needles 1546 above the skin of the user.

When the device is activated, the lever arm 1548 is rotated such thatthe needles 1546 enter the skin. This rotation turns the first tube 1542inside the second tube until the injection opening 1552 in the firsttube 1542 aligns with the reservoir opening 1554 in the second tube 1544allowing fluid to flow. The fluid flows from the reservoir opening 1554in the second tube 1544 through the injection opening 1552 in the firsttube 1542 into the center of the first tube to the fluid path in thelever arm 1548, down the lever arm to and out the needles 1546 into theuser's skin. The injection opening 1552 in the first tube 1542 islocated such that it opens the fluid path only when the needles 1546have entered the skin at the desired depth.

Because the rigid lever arm 1548 serves as the fluid path, the rotatingvalve embodiment does not require a flexible fluid path between thevalve and the needles. Also, the timing of the opening of the valve islinked directly with the position of the needles in the skin, therebyeliminating the possibilities of the valve opening before the needlesare properly positioned in the skin.

The fluid path and valving of the embodiments shown in FIGS. 75 through79 are simplified and reduced into fewer parts by integrating theactions of opening the valve and inserting the needles into the sameaction and part. Additionally, the tubes 1542 and 1544 need not becomplete circles but may be just arcs of circles. The fluid path may bea groove (not shown) down the outside of the first tube 1542 whichaligns with the reservoir opening 1554 in the second tube 1544. Thefluid path may also be a groove (not shown) down the inside of thesecond tube 1544 which aligns with the injection opening 1552 in thefirst tube 1542. The fluid path may further consist of a groove (notshown) in the inner wall of the second tube 1544 and the outer wall ofthe first tube 1542. In yet another variation, the lever arm 1548 couldbe attached to a rotating outer, or second tube 1544, with the inner, orfirst tube 1542 being stationary, such that the fluid flows from thefirst tube 1542 to the second tube 1544. In each variation, the valvetype is one of aligning holes and/or grooves by integrating the movementof the needle insertion with the valve which opens the fluid path.

In yet another rotating valve embodiment shown in FIGS. 80 and 81, theinfusion device can also use an improved rotating valve mechanismbetween a reservoir channel and a patient needle fluid path. FIGS. 80and 81 illustrate the valve assembly in a closed and open position,respectively. In FIG. 80, the fluid path openings 1557 and 1558 are notaligned due to the rotational position of the arm 1559. As the arm 1559is rotated in the direction of arrow A, member 1555 is rotated withinmember 1556 into the position shown in FIG. 81, such as when the patientneedles are seated, and the fluid path openings 1557 and 1558 becomealigned and allow fluid flow.

Returning to FIG. 1, a disk or Belleville spring 130 is also included inthe device 100 for applying an essentially even, constant force to thereservoir to force the contents from the reservoir, and is therefore,referred to as a constant force spring. As noted above, the constantforce spring 130 is used to store energy that when released byenergizing the device, pressurizes the reservoir at the time of use. InFIG. 1, the Belleville spring is held in a flexed state by a retentiondisk, handle or pin 135, that is positioned at the center of a pluralityof Belleville spring fingers. In doing so, the Belleville spring 130 isprevented from applying stress on the film 151 of the reservoir 150 orany remaining device components during storage.

When the retention pin 135 is pulled free of the Belleville spring 130,the fingers of the spring are released and exert a force on the film lid151 of the reservoir 150. The edge of the Belleville spring 130 istypically trapped about an outer circumference of the reservoir 150 andcan be configured to preferably create a pressure within the reservoirof from about 1 to 50 psi, and more preferably from about 2 to about 25psi, and most preferably from about 15 to about 20 psi for intradermaldelivery of the reservoir contents. For subcutaneous injection orinfusion, a range of about 2 to 5 psi may be sufficient.

For these values, it is desirable to hold constant, or near-constantinfusion pressure for the duration of treatment. The Belleville springmechanism 130 is one means of providing such a near-constant force,which can be translated to a near-constant pressure. As noted above, onemethod of loading a Belleville spring is to deflect the fingers of thespring and insert a pin through the enlarged inside diameter of theopening created. To return to a non-deflected position, the fingers mustfirst travel a distance that reduces the inside diameter, which is notpossible while the pin is in place, thus holding the spring in a loadedstate. Triggering the Belleville spring is then simply a matter ofremoving the pin, but because the fingers of the Belleville springinduce a significant frictional load on the pin, the force required topull the pin, even using a lever arm, can be substantial. If a “moment”is applied on the lever arm between the fingers and the pin, removalbecomes much easier.

In the improvement embodiment shown in FIG. 82, a Belleville spring 1560is shown, including a number of fingers 1562, a pin 1564, a lever arm1566 and a fulcrum 1568. When a force is applied to a distal end of thelever arm 1566, a reactionary force is induced on the Belleville springfingers 1562 at the fulcrum 1568. Further application of the force willrotate the pin 1564 until it pops free of the Belleville spring 1560,removing the pin 1564 as shown in FIG. 83.

A sample of several, but not all pin 1564 geometry configurations whichcan use this basic principle are shown in FIGS. 84( a), 84(b), and84(c), and include a circular pin (a), a broad lever pin (b), and anarrow lever pin (c) to provide rotational lifting. The round geometryas shown in configuration (a), allows a releasing force F₁ . . . F_(n)to be applied anywhere around the outer perimeter of the part (a), topor bottom, as shown in FIG. 85, to release the pin 84(a). The broadlever geometry as shown in configuration (b), allows a releasing forceto be applied at a substantially narrower perimeter of the part torelease the pin (b), as typically provided by a push button. The narrowlever geometry as shown in configuration (c), allows a releasing forceto be applied from the side of the lever (c), rather than the end. Inregard to configuration (a) of FIG. 84, application of the releasingforce at an extreme edge of the circular pin (a), as shown in the forcediagram of FIG. 85, results in a longer effective lever arm, thuslowering the required force.

Two factors that can influence where the force is applied are overallheight of the device, and ease of assembly in manufacturing. One methodof applying the force and release the Belleville spring is shown incross-sectional views of FIGS. 86 and 87. When in place within aninfusion device that is button activated, the button 1570 is typicallypushed to the right as shown, and the ramp 1572 applies the force on thepin 1564 via the lever arm 1566 to remove the pin 1564 from theBelleville spring 1560. Another version of this improved embodimentwhich can further reduce the required pull-out force, provides asplit-ring 1574 on the outside of the pin 1564 as shown in a perspectiveview in FIGS. 88 and 89. The split-ring 1574 would necessarily have alow coefficient of friction to allow removal of the pin 1564 from theinside diameter of the split-ring 1574, and be compliant enough tocollapse the split gap when the pin 1564 is removed as shown in FIG. 89,allowing the Belleville spring 1560 to activate.

In each of the above embodiments, the position and height of the fulcrum1568, relative to the center line and height of the pin 1564, arecritical to the function. In order to maximize the efficiency, thefulcrum 1568 should be positioned and scaled so that it will induceenough pin displacement such that the pin 1564 clears the Bellevillespring 1560, but requires a minimum amount of releasing force. Placingthe fulcrum 1568 farther from the centerline of the pin 1564 willprovide more pin displacement, but increases the releasing forcerequired on the lever arm to remove the pin 1564. Likewise, placing thefulcrum 1568 closer to the centerline of the pin 1564 will provide lesspin displacement, but decrease the releasing force required on the leverarm to remove the pin 1564.

In order to assure reliable operation in some applications, especiallythose having very pliable spring fingers, the mechanism must be designedsuch that the fulcrum spans more than one of the fingers of theBelleville spring. Configurations (a) and (b) in FIG. 84 therefore, arebetter suited for these applications than configuration (c) in thisregard. Conceptually, configuration (c) will work with a multitude ofnarrow, closely-spaced fingers, or it can be made to work by simplywidening the fulcrum 1568 only. If more than one finger of theBelleville spring 1560 is not spanned in some cases, the single fingerin contact may deflect independently of the other fingers and slidealong the pin 1564 without inducing the sliding of the pin relative tothe other fingers, resulting in a spring release failure.

FIGS. 90 through 92 illustrate an improved embodiment of the Bellevillespring 1580 which can be used in association with the improved pinrelease mechanisms described above and in place of the Belleville spring1560. The improved Belleville spring 1580 is typically sized betweenabout 1.15 to 1.50 inches in diameter, preferably 1.26 inches, and canfurther include a spring follower 1592 to allow for full reservoircontent delivery substantially as described above with reference toFIGS. 55 through 60. In the improved spring embodiment 1580 describedbelow, the Belleville spring includes a conventional spring body 1581,and an overmolded elastomer 1582 which covers the body 1581 and fills inthe otherwise open spaces between the spring fingers, such that as theBelleville spring 1580 travels between a flexed and relaxed position,the spring exerts a substantially uniform and constant force over theentire reservoir film surface. The overmolded elastomer fills in the“dead spaces” between the fingers of the spring without compromising theperformance of the Belleville spring.

The Belleville spring improvement embodiment 1580 shown in FIGS. 90through 92, can be provided as the primary fluid chamber pressurizationmechanism. The above infusion devices typically incorporate a Bellevillespring suited for administering a desired pressure on a fluid filledchamber when the Belleville spring is allowed to flex upon the chamberand thereafter, expel the fluid in the chamber by displacement. As shownin FIGS. 91 and 92, inherent in the design of the chamber is a rigidside of the chamber 1598 to provide structure to the chamber, and aflexible film side of the chamber 1594 which is deformable to accept thearms of the Belleville spring biasing into the chamber to displace fluidin the chamber. Though the Belleville spring and the chamber may besuitable for pressurizing the chamber and delivering the fluid, theBelleville spring is ultimately unable to fully conform to the shape ofthe rigid side of the chamber 1598 due to the rigid nature of both thechamber and the Belleville spring. This lack of conformity results insome fluid not being fully pushed out of the chamber when the spring“bottoms out” into the chamber. Such fluid loss is undesirable.

The improved Belleville spring embodiment 1580 of the present inventionincludes an assembly that seeks to address this fluid loss to somedegree by over-molding the Belleville spring 1580 with an elastomericmaterial, especially between the fingers of the Belleville spring 1580,such that the elastomer permits the Belleville spring 1580 to more fullyconform to the chamber. This allows the Belleville spring 1580 todisplace more fluid, as gaps between fingers are no longer present, andreduce fluid loss. An example of such a use of an overmolded Bellevillespring 1580 is shown in FIGS. 91 and 92. The elastomer filled areas 1582of the spring 1580 fill the “dead spaces” between the fingers of thespring without compromising performance.

The elastomer can be molded over the entirety of the Belleville spring1580 to create a spring with a compliant surface capable of permittingthe Belleville spring 1580 to both pressurize the chamber, and conformcompletely to the contours of the chamber to displace all the fluid inthe chamber. As shown in reservoir cross-sectional FIGS. 91 and 92, theBelleville spring 1590 further includes an overmolded elastomericfollower 1592, similar to the followers of FIGS. 55 through 60, butprovided as an overmolded surface to the Belleville spring 1590. Thefollower 1592 is provided and more closely conforms to the shapes in thereservoir, specifically the rigid side of the chamber 1598, such thatdead spaces are prevented as they are filled by the follower 1592 as theBelleville spring 1590 travels.

Adjacent to the Belleville spring 1590, a flexible film seal 1594 isprovided covering a fluid pocket 1596 positioned against a rigid chamberwall 1598. When released, the Belleville spring 1590 forces the contentsfrom the chamber as shown in FIG. 91. In the embodiment shown in FIG.91, the spring 1590 displaces the fluid in the pocket completely by“squishing” it out via the overmolded elastomeric follower 1592. Theadvantage of such an elastomer covered Belleville spring 1590 and springfollower 1592 described above is that it enhances the performance of theBelleville spring as a “squeegee” to ensure complete evacuation of thefluid in the chamber while not compromising its performance as apressurizer of the same chamber.

Another benefit associated with the use of a Belleville spring assemblyis the ability to use friction created by the Belleville spring in aproductive manner. For example, as shown in device cross-sectional FIG.93, the friction between the retaining pin 1635 and the Bellevillespring 1630 can be used to hold the device 1600 in an unreleased state.As shown in FIG. 93, an example device 1600 is shown having apush-button design wherein the activation and energizing of the device1600 is accomplished in a single multi-function/step process. FIG. 93 iscross-sectional view of an example patch-like injector or infusor systemthat is activated using a side push button 1605.

The device of FIG. 93 includes the push button 1605, an upper housing1610, a lower housing 1615, a reservoir pull valve assembly 1620, theBelleville spring 1630, the spring retention pin 1635, a manifoldassembly 1625, and a reservoir 1650. The device further includes aflexible spring follower 1655. The device can further include anadhesive surface 1616 having a cover 1617, which is secured with aneedle cap 1618 for one step removal. In the device shown in FIG. 93, asthe push button 1605 is pushed, two functions are achieved in an orderedand/or simultaneous fashion, rather than the three functions of thedevice of FIG. 1. First, the movement of the push button 1605 opens thepull valve 1620 allowing fluid communication between the reservoir 1650and the patient microneedles 1640 of the manifold 1625. The valve 1620can be comprised of any number of pull valves as described above.Second, the movement of the push button 1605 dislodges the springretention disk or pin 1635, releasing the Belleville spring 1630.However, the friction between the pin 1635 and the spring 1630, is alsobeing used to hold the rotatable reservoir 1650 in a retracted position.When the push button releases the Belleville spring 1630, one or moremanifold drive springs 1660 then rotate the reservoir 1650 downwardabout a hinge mechanism 1652, and drive drives the needles 1640 into thepatient's skin.

The push button 1605 is provided with a tapered surface 1606 whichfurther includes a slot 1608 (not shown) extending along a center of thetapered surface 1606 and through which the pin 1635 is allowed totravel. As the push button 1605 is pressed, the slotted tapered surface1606 is forced to travel past the pin 1635, which forces the pin 1635 upthe tapered surface 1606 and away from the spring 1630. The movement ofthe push button 1605 further serves to open the pull valve 1620. After ashort distance, which is sufficient to open the pull valve 1620, the pin1635 is lifted sufficiently to release the spring 1630 and the reservoir1650.

Specifically, the Belleville spring 1630 is held under tension duringstorage by the pin 1635 that interferes with the inner fingers of thespring 1630, and keeps them from moving any closer (i.e., reducing theinside diameter of the center opening in the Belleville spring). Thefingers must move closer as they pass through the center in order torelax. This allows a simple pin 1635 to be placed between the fingers(i.e., the inside diameter of the center opening in the Bellevillespring 1630) when it is flexed past center to hold the tension of thespring 1630. However, the device must also automatically insert theinfusion micro needles 1640 which are attached to the reservoir by wayof one or more separate drive springs 1660. These drive springs 1660 arecompressed for storage until the device 1600 is used, at which time theentire reservoir 1650 moves with the micro needles 1640 as they arebeing inserted.

In the embodiment shown in FIG. 93, the friction between the pin 1635and the Belleville spring 1630 is used as the means of holding the drivesprings 1660 under compression and the device 1600 in an unactivatedstate. The user activates the device 1600 by removing the pin 1635 fromthe Belleville spring 1630 via movement of the button 1605. The removalof the pin 1635 not only allows the released Belleville spring 1630 topressurize the reservoir 1650, but it also releases the reservoir 1650and needles 1640 to rotate downward under the force of the drive springs1660, and the movement is sufficient to insert the needles 1640 into thepatient's skin (not shown). The pin 1635 holds the tension on both theBelleville spring 1630 and the drive springs 1660, thus it requires onlya single motion to set in motion two completely different actions.

In other devices, the user is required to perform two or more differentsteps to accomplish the pressurization of the reservoir and the releaseof the patient needles. Still other devices have the button perform thetwo steps with one push from the user, but require a more complicatedbutton assembly to accomplish the correct timing of the actions. In theembodiment shown in FIG. 93, the timing is integral with the device.This is achieved by utilizing the Belleville spring and pin system asthe reservoir drive spring release mechanism, utilizing the friction ofthe Belleville spring 1630 fingers on the pin 1635 as the means ofholding the compression on the drive springs. The friction is eliminatedwhen the pin 1635 is removed from the Belleville spring 1630, therebyallowing the drive springs 1660 to push the needles 1640 into thepatient.

As noted above, the Belleville spring is allowed to flex upon areservoir to expel the fluid in the reservoir by displacement. As notedabove, the reservoir itself can include a rigid side and a flexible filmside which is deformable to accept the arms of the spring. However,reservoir improvements to materials and construction techniques can beprovided, as described in greater detail below.

In the typical infusion device, the reservoir is typically made of amaterial that has strong chemical and/or drug resistant properties. Thismaterial unfortunately does not bond well with other materials. Theimproved reservoir embodiments of the present invention shown in FIGS.94 through 100, introduces at least one other material which will bondwell to other materials, such as needles, and then includes a means tomechanically lock the non-bondable materials to this new material. Thisseparates the non-bondable materials, such as the reservoir 1700, whichcontains the strong drug resistant properties, from the bondablematerials, such as the needle hub/spring arm 1720 of FIG. 95. The twoseparate pieces then interface and act as one with each other via asealing interlock, such as an O-ring sealed lock 1730, or an elastomericsealed lock 1740 as shown in FIGS. 99 and 100, respectively. FIG. 94 isa view of a reservoir, and FIG. 95 is a view of a reservoir armproviding a fluid path. FIG. 96 is a perspective view of the reservoirarm of FIG. 95. FIG. 97 is an assembly illustration of the reservoir andarm of FIGS. 94 and 95, and FIG. 98 illustrates an assembled component.

The improved reservoir embodiments of the present invention includeproviding a reservoir 1700 and fluid path containing needle hub/springarm 1720, each being constructed of two separate molded parts. Thereservoir 1700 of FIGS. 94, 97 and 98, can be made of a material thathas strong chemical and/or drug resistant properties. The needlehub/spring arm 1720 and resulting fluid path 1724 of FIGS. 95, 96, 97and 98 can be made of any number of plastic materials, and can include asingle film seal along the fluid path 1724 between the valve exit hole1722 and the needle openings 1726. The reservoir 1700 can then beassembled with the needle hub/spring arm 1720 via a compatible valvemechanism 1730 or 1740, shown in FIGS. 99 and 100. FIGS. 99 and 100illustrate a first and second valve 1730 and 1740 for use with theassembly of FIGS. 94 through 98.

In the typical infusion device, the configuration of the reservoir andneedle hub/spring arm includes a reservoir and fluid path constructed ofone part. However, as noted above, the reservoir 1700 is typicallyrequired to be made of a material that has strong chemical and/or drugresistant properties. This material unfortunately does not bond withother materials (i.e., the needles) very well. The advantage ofseparating the two pieces as shown in FIGS. 94 through 97, allows foreasier assembly of the needles 1728 to the spring-arm hub. They can beinsert-molded or bonded, instead of mechanically fixed into anon-bondable material.

Sealing interlock examples for completing the assembly shown in FIG. 98are shown in FIGS. 99 and 100. In FIG. 99, a valve plunger rod 1732 ispositioned within a cylindrical opening 1734 in the spring arm/fluidpath housing 1720. The spring arm/fluid path housing 1720 includes areduced diameter member 1736 which is mated with an opening 1702 in thereservoir 1700, and sealed with an O-ring 1738. The rod 1732 includes anumber of ribs 1733 and an enlarged proximal end 1739 which functionssubstantially similar to those described above with reference to FIGS. 5and 6. In FIG. 100, the O-ring seal 1738 is replaced with an elastomericexterior seal 1748 about the outside surface of the reduced diametermember 1736. The remaining valve functions are substantially asdescribed above in regards to FIG. 99.

This use of non-bondable and bondable material engagement is furtherincorporated in the following additional improved needle hub embodimentsof the present invention. The embodiments use a two shot molding processwhich has the ability to have two or more thermoplastics of dissimilarnature create a fluid seal. Since the materials in question aredissimilar, they inherently resist being bonded to each other. In anormal two shot molding process, a seal is typically created via theadhesive nature of the plastics being used. In the case of the improvedhub embodiments described below, there is no adhesive nature between theplastics, therefore a number of unique designs are utilized to create apressure fit, and thus a fluid seal.

In FIG. 101, a cross-sectional view of a completed bond 1750 is shown,and includes a fluid path 1752, a film seal 1754, and a first shot mold1760. A second shot mold 1758 is then disposed about the first shot mold1760 and secures the needles 1756. The first shot mold 1760, as shown inFIG. 101, is molded having protruding dovetail configurations to providea mechanical lock with the second shot mold 1758 as the second shot moldcools and shrinks about each dovetail.

Specifically, following appropriate cooling and standard multi-shotmolding procedures, the second shot mold 1758 is done in a material withdesirable processing characteristics such as polycarbonate. The firstshot is done, in this case, in a transparent, clear plastic material.The transparent, clear plastic material is preferably a cyclic olefincopolymer (CCP) that is characterized by high transparency and clarity,low extractables and biocompatibility with the substance contained inthe reservoir. This material is by nature incapable of bondingadhesively to another material such as polycarbonate and the like.

The geometry for the CCP first shot, as shown in FIGS. 102 through 105which are cross-sectional views of completed molding assemblies 1751,1753, 1755 and 1757, can include any number of dovetail and lockingconfigurations. In each case, after appropriate cooling of the firstshot, the second shot is done in a material, such as polycarbonate, andis injected around the dovetails such that they encompass each dovetail.When the second shot material shrinks, as all plastics do to somedegree, it will put pressure on the sloped surfaces of the dovetail andhave the effect of “pinching” the dovetail. This pinching creates thetight fluid seal between the two dissimilar materials that wouldotherwise be incapable of creating a fluid seal between them.

The improved embodiment of the present invention described above isfurther capable of creating a continuous fluid path in a single partover two different material types (i.e., 1760 and 1758). This reducespart count which reduces cost, as it would otherwise have to be donewith a snap fit and potentially a sealing member, such as an O-ring.This would not only increase the cost due to part count, but furtherincrease the manufacturing complexity as well. Additionally, theconstruction can take advantage of the desirable characteristics of twoor more different materials and reduce compromises that would otherwisehave to be made if construction was done in only one or the othermaterial.

For example, by molding the first shot (i.e., 1760) in a material suchas CCP, the embodiment can capitalize on the beneficial drug carryingcapabilities of the material. Unfortunately, the material does notexhibit practically any other common, positive manufacturing orprocessing attribute. For example, CCP is difficult to bond withneedles. Therefore, the second shot (i.e., 1758) can be done in amaterial such as a polycarbonate, which readily bonds needles to thepolycarbonate, and further does not have adverse effects on the drugwhich is contained in the parts made of CCP.

It will be appreciated that this concept of creating a fluid sealbetween two somewhat dissimilar materials can be accomplished in severalways. The underlying principle is channeling or harnessing the shrinkingof one material against a surface of a second material in such a fashionas to induce a tight, pressure induced seal between the materials. Thisis achieved in the embodiments of the present improved feature inventionby using variants on the dovetail concept. As shown in FIGS. 103 through105, in the modified locks, shrinkage against vertical and perpendicularsurfaces also can be used to create a sufficient fluid seal.

The concept can be further refined to include improvements for highvolume molding, assembly, and automation processes. The dovetailarrangement represents an improvement over earlier concepts in severalways, including the simplification of the molding process and using theshrink in thermoplastic molding operations to create a pressure sealbetween dissimilar materials. The ability to bond with patient needlesis further developed in the improved hub embodiments described ingreater detail below.

Each embodiment of the infusion device described above contains at leastone or more patient needles, or microneedles. Each microneedle ispreferably at least 31 gauge or smaller, such as 34 gauge, and isanchored within the patient needle manifold and can be used to targeteither an intradermal or subcutaneous space as required by the specificapplication.

The patient needles are positioned in the patient needle manifold, whichincludes at least one fluid communication path to each patient needle.The manifold may simply have a single path to one or more patientneedles, or may provide multiple fluid paths routing contents to eachneedle separately. In the embodiment of the improvement shown in FIG.106, a mini needle hub 1770 is constructed to secure a needle 1772 andto then be snap fit into a corresponding needle manifold 1771.

In a micro infusion device, a drug reservoir typically has attributessuitable for storing and sustaining drugs in liquid form. The samereservoir, however, due to the drug storing attributes, hascharacteristics not well suited for peripheral manufacturing processesnecessary to create a robust drug delivery device. Although it isdesirable to have the fluid reservoir have direct communication with theneedles which will eventually deliver the drug to a patient, thethermoplastic which is used to store the drug is not easily bonded toother materials. Thus, as noted above, it is nearly impossible to bondneedles to the same reservoir material and create the desired fluid pathwithout the needles potentially falling out due to the lack of a strongbond.

The improved hub embodiment of the present invention shown in FIG. 106,solves this problem by isolating the needle hub portion 1770 of thereservoir as a separate part. By doing this the separated hub 1770 canbe configured to function properly (i.e., as a secure needle manifold),as can be the drug reservoir (i.e., as a biocompatible reservoir) (notshown). Unfortunately, when a single complex part is constructed as twosimpler parts, this actually adds overall cost due to the increases intools, handling, storage (i.e., stock keeping units or SKUs), and thelike. However, the improvement embodiment shown in FIG. 106, by itssimple manufacturing attributes, can save resources in the long run.

The hub 1770 can be molded in standard, uncomplicated mold tools at highcavitation. It can be automated at high speeds and can be molded in amaterial suitable for bonding with needles, such as needle 1772. The hub1770 is further independent of large amounts of handling due toorientation requirements, and can be mechanically attached to themanifold 1771 with snap fits provided by a tapered surface 1773,eliminating costly materials and processes. Additionally, the embodimentpermits easy testing of the continuity of the fluid path prior to actualinsertion of the hub 1770 into the manifold 1771.

As noted above, the microneedles of the devices can be of differinglengths or gauges, and can contain one or more ports along a bodylength, needle tip, or needle bevel. As such microneedles are used fordelivery of medicine, they can occlude for a variety of reasons. In yetanother improved needle embodiment of the present invention, amicroneedle is provided which can assist in delivery of the medicinedespite possible occlusion.

A first variation of the improvement embodiment is shown in a needleside view in FIG. 107, wherein the needle 1811 is constructed using aporous material along at least a portion of the needle body, providingfluid communication between the inside and outside of the needle to adesired degree. Therefore if the needle 1811 tip is plugged, flow canstill occur through the porous material. A second variation of theimprovement embodiment is shown in FIG. 108, wherein the needle 1813uses a number of tiny holes 1817 along at least a portion of the needlebody, preferably around the tip of the needle 1813, aside from the mainexit orifice 1819. This allows flow via the tiny holes 1817 if the tipbecomes plugged. Each variation can be accomplished by using either aporous material in construction, or by adding the holes later.

Needle improvements, Belleville spring improvements, and material usageimprovements can also be applied in devices having activationimprovements as described in greater detail below. In a further deviceimprovement shown in FIGS. 109 and 110, improved activation andenergizing of the device is accomplished in a singlemulti-function/step, and timing is precisely controlled by using a pivotarm 2770 to both access the reservoir and a patient skin surface atsubstantially the same moment. FIG. 109 is cross-sectional view of afirst embodiment of such a patch-like injector or infusor system in anunactivated state, and FIG. 110 is cross-sectional view of theembodiment shown in an activated state.

The device of FIG. 109 includes an upper and lower housing (not shown),a reservoir septum assembly 2740, a patient needle manifold assembly2750, and a reservoir 2760. The pivot arm 2770 is also provided,extending between the manifold 2750 and a valving needle 2780. Anactivation mechanism 2790 is shown, which can consist of any number ofdevices such as the push button of FIG. 1.

In the embodiment shown in FIGS. 109 and 110, as the device activates,two functions are achieved in a sequenced and/or simultaneous fashion.First, the activation mechanism 2790 releases the manifold 2750 which isthen driven by one or more manifold springs 2795, allowing the pivot arm2770 to rotate about the pivot 2775. Second, the rotating pivot arm 2770seats the patient needle manifold 2750 against the patient's skin 2751,and also drives the valving needle 2780 into the reservoir septum 2740.In doing so, the rotating pivot arm serves as a fluid communication pathbetween the reservoir 2760 and the patient needle manifold 2750. Thisembodiment therefore penetrates the microneedles into the patient skin2751 and opens a valve to inject the drug all with a single action, suchas the simple push of a device button (not shown), and additionallyprovides the transfer of the fluid between the reservoir and thepatient.

The improvement embodiment shown in FIGS. 109 and 110 includes the pivotarm 2770, or tube, which includes a number of injection needles 2753 ata substantially perpendicular angle at one end, and the single valveneedle 2780 pointing in the opposite direction at the other end. Thetube of the pivot arm 2770 has the pivot point 2775 between the two endsthat allows the infusing needles 2753 a range of movement necessary topenetrate the patient's skin 2751, while also allowing the valvingneedle 2780 to penetrate the septum assembly 2740 leading into thereservoir 2760. The pivoting action is powered by one or more springs2795 and is held in the armed position by the activation mechanism 2790.

As shown in FIG. 110, when the activation mechanism 2790 is activated,the spring 2795 starts to rotate the tube of the pivot arm 2770 aboutthe pivot point 2775. As the tube of the pivot arm 2770 pivots, the endof the tube with the infuser needle manifold 2750 moves down, pushingthe needles 2753 into the patent's skin 2751. The other end of the tubeof the pivot arm 2770 moves up, pushing the valving needle 2780 throughthe septum 2740. When the valving needle 2780 penetrates the far side ofthe septum 2740, the drug is released from the reservoir 2760 and passesthrough the valving needle 2780, down the tube of the pivot arm 2770 andout the infusion needles 2753 of the manifold 2750 into the patient. Thedrug will flow because the reservoir 2760 is pressurized at some pointbefore, or at the same time, the activation mechanism 2790 is pushed,using any of the pressurization techniques described above.

This improved activation embodiment of the present invention is asimpler device and includes a reduced number of parts relative toconventional devices and as such, is easier to assemble. For example, inconventional devices the infusion needles and the valving needle moveperpendicular to each other and are typically connected by a tube. Thisimprovement embodiment replaces the three commonly found moving parts ofthe fluid path in other embodiments, that is, two pieces sliding atright angles and a flexible piece, with one moving part consisting ofthe single continuous rigid rotating piece 2770. The flexible tubing,which can be hard to assemble, is replaced with an easier to assemblerigid part.

In yet another improved activation embodiment shown in FIGS. 111 through115, the device can use the attractive or repelling forces of magnets toapply a force on a fluid and drive it through a fluid path. Theseembodiments can also be used to magnetically apply the force required todrive the needles into the skin. Potential energy of the magnets insidethe system does not dissipate over time, and the magnets can beseparated sufficiently to reduce their attractive force on each otherand their force exerted on the polymer that contains them, therebyreducing creep. The magnet separation distance and the strength of themagnets can be adjusted in strength to optimize the mechanism.

As shown in the cross-sectional device view of FIG. 111, the device 1800has an upper housing 1805, a lower housing 1810, a film-covered fluidreservoir 1815, a fluid path 1820, and an activation mechanism 1825.When activated (i.e., the mechanisms 1825 moved free of magnet 1805 viaa button or similar means), the attractive forces of the magnetic upperand lower housings 1805 and 1810, respectively, coming together forcesthe contents from the reservoir 1815 via the fluid path 1820 and into apatient via needle 1822. In the cross-sectional device view of FIG. 112,the repellent forces of a first and second magnet are used to force thecontents from a reservoir positioned above the engaged magnets.

As shown in FIG. 112, a clear-covered fluid chamber 1830 is positionedabove a piston 1835 engaged with an upper magnet 1840 (in this example,having an N pole above and an S pole below). The upper magnet, whenactivated, is repelled by a lower magnet 1845 (in this example, havingan S pole above and an N pole below), forcing the piston 1835 into thecontents of the chamber 1830. The contents are forced through an opening1850 (which can be furthered valved as described above) and to amanifold 1855. The manifold can be constructed of a material with a lowresistance to movement when driven by the manifold spring 1860, such aspolypropylene or polyethylene.

In yet another activation improvement embodiment shown in a devicecross-sectional view in FIG. 113, the device includes an upper housing1865, a lower housing 1870, a fluid reservoir 1875 (i.e., clear fluidchamber), a fluid path 1880, and an upper and lower magnet 1882 and1884, respectively. The magnet of 1882 or 1884 can be replaced with asteel plate (not shown) which would also achieve the attraction forcerequired. When activated (i.e., via a button or similar means), theattractive forces of the upper and lower magnets 1882 and 1884, ormagnet and plate, coming together forces the contents from the reservoir1875 via the fluid path 1880 and into a patient via a needle 1881. Acenter-fired patient needle mechanism incorporating any number ofmechanisms described above, can be used to seat the needles 1881 duringactivation and results in a minimum of dead space.

In yet another activation improvement embodiment shown in the pre-useand post-use side view FIGS. 114 and 115, the device includes a magneticupper housing 1890 that includes a number of needles 1894, and amagnetic lower housing 1892 having a number of openings (not shown)concentric with the needles 1894 and each having a diameter sufficientto allow each needle 1894 to pass. Once again, the magnet of 1890 or1892 can be replaced with a steel plate which would also achieve theattraction force required. When activated using a mechanism 1896 (i.e.,displaceable via a push button or similar means), the attractive forcesof the upper and lower magnets 1890 and 1892, or magnet and plate, forcethe needles 1894 through openings in the lower housing 1892 and into thepatient skin surface 1895 as shown in FIG. 115.

The devices above each function to infuse a substance via the patch-likedevice. Once positioned on a user and activated, the user typicallyleaves the device in position, or “wears” the device, for some period oftime, and then removes and discards the device with no damage to theunderlying tissue. However, upon intentional or accidental removal, oneor more safety features can deploy as described in greater detail belowto shield the exposed needles resulting from activation.

In general, a passive safety system is most desirable. This allows thedevice to be self-protected in case of accidental removal or if the user“forgets” that there is a safety step. Since a typical use for thisdevice is for providing human growth hormone, which is usually given inthe evening, it can be expected that users such as children that wearthe device may actually wear them overnight, even though the delivery inthis case is only expected to take less than 10 minutes. If the devicefalls off during this time, without a passive system, the needles couldre-stick the user or caregiver. The solution is to either limit theactivities during use, or include a passive safety system.

With respect to safety systems there are typically three options. Afirst option is to retract the needles into the device. A second optionis to shield the needles to remove access, and a third option is todestroy the needles in a way that prevents needlestick. Althoughversions of each can be constructed, no substantially viable method ordevice exists to destroy the needles that does not substantially riskbreaking a needle and exposing the user to needlestick. Other systems,such as active systems, explore a manual shielding and/or destruction,or manual release of safety features with an additional button push orsimilar action. A detailed description of passive embodiments of thepresent invention are outlined below, followed by a detailed descriptionof active embodiments of the present invention.

To prevent inadvertent or accidental needle sticks, intentional re-useof the device, and to shield exposed needles, a locking needle safetymechanism can be provided and activated automatically upon removal ofthe device from the skin surface. The improved safety mechanismembodiments can be provided in a number of versions, including a“mouse-trap” type safety (passive), a needle lift-and-cover type safety(active or passive), and a rotating needle manifold type safety (activeor passive).

Still other improved safety mechanism embodiments described belowinclude spring loaded, pivoting transverse barrier mechanisms with andwithout a “ratchet” style lock feature (passive), manual flip top,snapped or glued down transverse barrier mechanisms (active), pull outand lock shield mechanisms (passive), spring loaded lift converting totransverse barrier (passive), spring assisted, slotted needle retraction“sled” (passive or active), torsion spring to lift the needles out(passive), hinged flat shield with and without adhesive (passive), andbending needles following use safety (active or passive) and a bi-stableleaf spring (active or passive).

The first improved safety embodiment of the present invention, ormouse-trap safety, is shown in FIGS. 37 through 41. In this safetydevice embodiment in a ready, or biased state, a sleeve which isintegral to a spring (i.e., a safety spring), is retracted and permitsexposure and use of the needles. When the device is removed from theskin the spring deflects to its unbiased state, and extracts andpositions the sleeve about the needles in such a way as to encase andshield the needles.

In a first example mouse-trap safety device shown in FIG. 37, thepush-button device 700 is shown wherein the activation and energizing ofthe device is accomplished in a single multi-function/step process asdescribed above. FIG. 37 is cross-sectional view of an examplepatch-like injector or infusor system that is activated using a sidepush button and including the first improved safety embodiment of thepresent invention.

The device of FIG. 37 includes the push button 780, the upper housing705, the lower housing 770, a mouse-trap door 790, a door latch 791, anda door pivot point 792. A flat spring 793 and a shield 794 are alsoprovided and more clearly shown in FIG. 38. As the push button 780 ispushed, the movement of the button 780 opens at least one valve 750,dislodges the spring retention disk or pin 730, and removes a supportmember (not shown) from the patient needle manifold 745 allowing themanifold 745 to travel. The movement of the push button 780 alsoreleases the door latch 791, however, as the device is adhesivelypositioned against a user's skin, no movement of the door 790 isallowed.

One aspect of this embodiment of the present invention is that in thisstate, the safety spring 793 is in a constant state of exertion towardsan unbiased state (i.e., the state shown in FIGS. 38 through 41). Thisconstant exertion is countered by the surface upon which the device isattached (i.e., the skin of the patient) and the adhesive used to attachit. Therefore, the safety spring 793 is known to be working in a mannercounterproductive to embedding needles 760 in a patient and keeping themembedded for a desired amount of time. This force however, is necessaryto the functionality of the mechanism, since it is this exerted spring793 force which ensures eventual shielding of the needles 760 when thedevice is removed from the skin surface. Therefore to counter thisforce, a further aspect of the embodiment of the present invention isthe inclusion of what could best be described as the mouse-trap door790.

The mouse-trap door 790 acts to trap the safety spring 793 in such a wayas to reduce the amount of force actually transmitted to the skinsurface by the safety spring 793. The trap door 790 uses principles ofleverage (such as those found in a common mouse trap) to produce amechanical advantage of the door 790 over the safety spring 793. Thus,when the door 790 is folded over the safety spring 793, the safetyspring 793 puts pressure at a predetermined spot on the door 790 whichis at a predetermined distance from the door hinge 792, which reducesthe force of the safety spring 793 by a multiplier of the ratio of thedistance between the pressure point of the safety spring 793 and thehinge 792 of the door 790. When in use, the skin surface will then seeonly a fraction of the actual force of the safety spring 793 rather thanits full force.

When the device is removed from the skin surface however, the trap door790 is urged away from the device by the safety spring 793 as it travelsto its fully deployed state as shown in FIGS. 38 through 41. The initialforce of the safety spring 793 on the door 790 is light due to themechanical advantage of the door 790 being hinged at 792. However, asthe door 790 is urged and pivots away from the device, the mechanicaladvantage is proportionately reduced. The safety spring 793 will, as aresult, accelerate such that the full strength of the safety spring 793is realized at or near the end of its length of travel. This safetyspring 793 strength is necessary to ensure that any locking mechanism,such as a first detent means (not shown) on the safety spring sleeve 794and any second detent means (not shown), can be engaged and locked usingthe safety spring 793 force to overcome the resistance of the detentmeans. In the end, when the safety spring 793 is fully deployed, thespring sleeve 794 will be shielding the needles 760 and the detent meanswill not permit retraction, and subsequently prevent access or reuse ofthe needles 760.

The second improved safety mechanism embodiment, or needlelift-and-cover, is shown in FIG. 116 and can incorporate what iscommonly known as a scotch-yoke 1950 or a “crank and slotted crosshead”. Additional details of such a method are disclosed in a textentitled Ingenious Mechanisms for Designers (Industrial Press), page251, the relevant contents of which are incorporated herein byreference. In this embodiment, the needle manifold 1956 is coupled witha spring loaded crank 1952. The crank 1952 has a pin 1954 incommunication with the manifold 1956 such that as the crank 1952rotates, the manifold 1956 is driven downward to embed the needles (notshown). The crank 1952 is stopped in rotation coincident with a pointrepresenting the full embedded depth of the needles to allow the fluidto be delivered. Upon removal of the device from the users skin whichallows a slight further manifold 1956 travel downward, the crank 1952 is“released” and allowed to continue rotation which, according to theprinciples of the scotch-yoke, will withdraw the needle manifold 1956back out of the skin to a safe position.

As shown in FIG. 116, the lifting is achieved using a scotch-yokemechanism which is engaged with the patient needle manifold 1956, and isshown in a pre-use position (a), a substantially in-use position (b) anda post-use position (c). A torsional spring 1952 is provided with a pinor cam arm 1954 having a cam driven through a slot of the manifoldmember 1956. As the spring 1952 exerts a rotational force, the arm 1954drives the manifold 1956 into the skin surface (not shown) which alsoblocks further travel of the arm 1954. When removed, the arm 1954 isfree to travel and in doing so, lifts and retracts the manifold 1956.

The mouse-trap and scotch-yoke type embodiments of a safety mechanismare passive systems, which require no additional steps by the user torender the needles safe. Such passive systems must use some means totrigger the deployment of the safety mechanism, and the most effectivepassive systems are those that sense proximity to the skin surface andwhen removed from the skin surface, deploy the safety mechanism. This“sensing” of the skin implies a direct relationship between the elementthat senses, and the element that is deployed. The embodiments describedabove improves upon conventional passive safety designs by reducing theforces of the safety mechanism realized on the skin by the user toimperceptibly low values.

Yet another embodiment of the present invention which includes liftingthe needle or needles back out of the skin after they have been deployeduses a ramp mechanism as shown in FIGS. 117 through 122. As noted above,the microinfusor includes at least one drive spring which acts to embeda needle or an array of needles into the skin of the user. The drivespring, by design, is positioned in such a manner that it can drive theneedles into the skin. In the embodiment shown in FIGS. 117 and 118,when the infusion is complete, a mechanism such as a ramp 1004 can beprovided and positioned to allow the user to engage the ramp 1004 withthe manifold 1000 or head of the needle or needle array, and by pushingthe ramp 1004 toward the manifold 1000 the needles (not shown) can beramped up or lifted back out of the skin of the user. If the drivespring (not shown) however, is allowed to stay in position exertingforce on the manifold 1000 of the needles, then this lifting of theneedles is done against the force of the drive spring.

As shown in FIGS. 117 and 118, a passive retraction wedge design isshown having the patient needle manifold 1000 having a substantiallyround pin 1002 extending from opposite sides thereof to engage anincline of the ramp 1004 when the ramp is driven toward the manifold1000 by a spring 1008. The ramp 1004 is secured from prematurely liftingthe manifold 1000 by slots 1012 secured by an adhesive skin sensingpull-out member 1006. The entire assembly is disposed within an infusiondevice as described above. After use, the device is removed from theskin and the adhesive pull-out member 1006 is pulled downward out of thedevice as it is stuck to the skin surface (not shown). When this occurs,the slots 1012 of wedge 1004 are released from the pull-out member 1006and the wedge 1004 is driven against the pins 1002 of the manifold 1000as shown in FIG. 118. This lifts the manifold 1000 and the needles (notshown) are retracted into the device and the needle opening is coveredinternally by the wedge 1004.

In this embodiment, the wedge 1004, or shield, is a molded part and ispositioned between an activation button (not shown) and the manifold1000. The spring 1008 is also positioned between the wedge 1004 and thebutton. The spring 1008 is preloaded only enough to compensate for thedifference in travel between the button and the necessary travel forretraction. The wedge 1004 is held in place by the skin-sensing pull-outmember 1006. The skin-sensing pull-out member 1006 is held by a slidablebutton component (not shown) in the side notches 1014 of the pull-outmember 1006.

When the button is pressed, it moves until there is a gap that releasesthe side notches 1014 of the skin-sensing pull-out member 1006 componentand simultaneously compresses the spring 1008 to its full displacement.The skin-sensing pull-out member 1006 stays in place due to the presenceof the skin. The manifold 1000 is released and seats the needles in theskin. Upon removal from the skin the adhesive on the large surface areaof the skin sensing pull-out member 1006 pulls outward and this in turn,releases the wedge 1004, which is now under spring load. The wedge 1004moves forward, lifting the manifold 1000, retracting the needles andcovering the access hole.

In this embodiment, there is a force-balance issue, which can becontrolled. The spring 1008 that drives the wedge 1004 loses force as itexpands. The manifold drive spring (not shown) disposed above andpressing down on the manifold 1000 is increasing in force as it iscompressed by the lifting of the manifold 1000 by the driven wedge 1004.This can be overcome with a very strongly biased wedge spring 1008,however this negatively impacts the force required to press the pushbutton.

Therefore, another version of the above embodiment is shown in FIG. 119.The concept of this embodiment includes the manifold 1000 and a carriage1005 that are launched forward together. The manifold drive springs (notshown), drive the carriage 1005 directly, and the manifold 1000 iscoupled with the carriage 1005. The wedge 1004 in this case, is used tothen separate the manifold 1000 from the carriage 1005 upon safetyrelease by pushing the manifold free of detents 1007. Thus the drivesprings of the manifold do not need to be overcome, as they remainexerted against the now independent carriage 1005.

Yet another version of an improved design is to use the initial travelof the wedge 1004 to push the drive springs of the manifold 1000 out ofline so that they are buckled and can no longer exert a normal load onthe manifold 1000 during retraction. Both of these versions also have abenefit in that the manifold 1000 can not be re-fired and reused.

In the embodiments of FIGS. 117, 118 and 119, the shielding is passiveand completely covers the needles with material. It is constructed ofmolded parts with a high degree of strength and does not apply force tothe skin surface during injection or affect adhesive presence at theneedle area. The needles are held internally after use and the spring1008 is minimally loaded over life. The embodiment does require a forcebalance such that the expanding spring 1008 compresses the drive springand a skin adhesion area is required to release the safety shield.Therefore, low skin adhesion or high friction can be of concern.Additionally, three parts are included, contributing to assemblycomplexity and the need for a long throw to work (i.e., increased devicesize). Also, as with most compressed spring mechanisms, such springs canbe subject to creep.

The ramp element 1004 included in this embodiment of the presentinvention includes a ramp profile which is shallow enough to overcomeboth the friction on the ramp (i.e., friction between pins 1002 and ramp1004 while lifting manifold 1000), and the force of the drive spring(i.e., force urging the manifold 1000 downwards), without being soshallow that the “throw”, or translation of the button is adverselylong. As noted above, a further aspect of this embodiment is the use ofthe translation of the ramp to affect the manifold spring, such as to“knock the drive spring of its perch” above the manifold 1000. Thisembodiment employs structures (not shown) necessary to not only lift theneedles out of the skin, but to also dislodge the drive spring (notshown) from its engagement with the needle manifold 1000, thuseliminating the force exerted by the drive spring and making thecorresponding lifting of the needles easier.

A further aspect of this embodiment is the inclusion of structures whichwould provide a transverse barrier over the needles when they have beensuccessfully lifted out of the skin and are back in the device. Theseneedles are typically small enough that they require special features toensure they embed properly into the skin of the user. These needlefeatures, by nature extend beyond the bottom of the device and unlessfully retracted, would be difficult to cover with a simple transversebarrier which could otherwise bend and break off the needles. Thisembodiment of the present invention therefore, provides for lifting theneedles such that a transverse barrier, in this case the ramp itself,can be deployed without breaking the needles off, as broken needlescould be harmful in the environment.

Still another embodiment of the present invention similar to thescotch-yoke type, includes a mechanism for lifting the needle or needlesback out of the skin after they have been deployed using a V-slotmechanism as shown in FIGS. 120, 121 and 122. In the passive retractionslot design of this embodiment of the present invention, the user beginsoperation of the device by pressing the manifold to activate the device.After delivery, the user removes the device from the skin and theadhesive pulls a small lock out of the path of the main slide. Themanifold is then retracted into the device and the hole through whichthe needles protruded is covered by the slide.

As shown in FIG. 120, a passive retraction slot design is shown having aslide 1015 having a pin 1016 extending from opposite sides thereof toengage a V-slot 1020 formed in a member 1022, and is driven within theslot 1020 by a pair of springs 1025. The entire assembly is disposedwithin an infusion device as described above. As noted above, the userbegins operation of the device by pressing a means, such as the manifoldor a button (not shown) substantially as described in the aboveembodiments,) to compress the springs 1025 as shown in FIG. 120. Oncethe device is activated by a release means, such as a user push button,the springs 1025 are released and drive member 1022 forcing the slide1015 toward the skin surface as guided by slots 1020. The slide 1015travels to the point of maximum needle insertion and is stopped fromfurther downward travel by the skin surface (not shown), stopped fromrearward travel by the springs 1025, and stopped from further forwardtravel by the ramped protrusions of the slots 1020. When the device isno longer in contact with the skin, the slide 1015 is pushed down freelyand travels further forward into the upward slope of slots 1020. Thetravel of the slide 1015 then exerts upward force on the manifolddisposed beneath the slide 1015 (not shown) and retracts the needlesback into the device and covers the hole, completely enclosing theneedles.

This embodiment provides complete covering of needles with material andcan be molded having very high strengths. Very little force is appliedto the skin during injection and the mechanism does not affect adhesivepresence at needles. The needles are safely held internally after use,such that the embodiment clearly provides visual feedback of “in use” or“used” states, and requires no extra parts. However, skin adhesion isrequired to release the safety, therefore low stick or high friction canpresent difficulties. Additionally, as with the above embodiment, theneed for a long throw to work (i.e., increased device size) is present.Also, as with most compressed spring mechanisms, such springs can besubject to creep, and there can be concerns about high forces held overthe device life and the rate of deployment.

Another improved safety embodiment of the present invention is a passivefully enclosed shield as described below. FIG. 123 is a perspectivebottom view of a device, illustrating a view of an embodiment of abucket-type safety shield feature of an infusion device beforeactivation, and FIG. 124 is a perspective bottom view of a device,illustrating a view of the bucket-type safety shield feature afteractivation.

The rotating shield 1030 can be powered by a preloaded torsion spring1032 and remains loaded in an “up” rotated position until the pushbutton 1042 is pressed. The shield 1030 is then released and free torotate, but is prevented from rotating to a full deployment position bythe presence of the user's skin against the adhesive covered surface1045 of the device. When the device is no longer against the user'sskin, such as when the device is removed or falls free, the shield 1030is no longer obstructed by the skin surface and rotates about 180degrees, and is thereafter locked into place, fully covering the patientneedles 1040 and preventing needle stick injuries.

As shown in FIG. 123, the needles 1040 are originally recessed within anopening 1035 on the lower, adhesive covered surface 1045 of the device.The user secures the device on the skin with the adhesive surface 1045and then presses the activation button 1042 to activate the infusiondevice. When the device is removed, the shield 1030 flips down and locksin place over the needles 1040 to prevent the user from seeing ortouching the needles.

The shield 1030 is a stamped and formed sheet metal part that ispre-loaded with the torsion spring 1032. As can be seen in FIG. 125illustrating a perspective view of the opened lower housing of thedevice showing the shield 1030 retracted within the device, the frontedge of the shield 1030 includes a lock arm 1034 that rests on a crossbar member 1036 of the device, thus holding it fixed. When the button1042 is activated as shown in FIG. 126 illustrating a perspective viewof the opened lower housing of the device showing the shield 1030 readyto rotate, the tabs 1044 on the button 1042 push the lock arm 1034 offthe cross bar member 1036 to allow the shield 1030 to rotate under theload of the spring 1032 when clear of the skin surface. FIG. 127illustrates a perspective view of the opened lower housing of the deviceafter the shield 1030 is rotated. The tabs 1044 extend from the pushbutton 1042 to also help prevent pinching of the skin between the pushbutton and the cross bar member 1036 during activation.

In yet another release embodiment, an additional arm (not shown) isprovided at substantially 90 degrees to the lock arm 1034. This armwould point along the axis of movement of the button and hold the shield1030 fixed before use. When the button 1042 is pressed, cam feature(s)(not shown) on the button 1042 push the additional arm sideways so thatit can drop through a slot and release the shield 1030 with only a smallforce applied. This also helps remove the tolerance sensitivity ofbutton 1042 position while allowing the shield 1030 to rest lower in thedevice. This also can provide more room for the torsion spring 1032 andrequire less device height.

While the infusion device is administering the dose, the shield 1030 ofFIGS. 123 through 127 rests on the skin surface. When the device isremoved, purposely or accidentally, the bucket-type guard 1030 flipsthrough the opening 1035 due to the torsion spring 1032 and locks over atab 1046 in the hole 1048 where the spring pin was removed duringactivation.

In this embodiment, the lock is achieved with the lock arm 1034 and/orsnap configuration located at the front of the shield 1030. The force toengage the shield lock pushes the lock arm 1034 outward across the smalldimension of the cross-section thus keeping the force low. The force todefeat the shield 1030 is applied across the large dimension of thecross-section normal to the movement of the lock. This allows the forceto engage the lock to be low while requiring a much higher force todefeat the lock.

The torsion spring 1032 can be loaded onto a pin (not shown) on theshield 1030, and a spring arm can be locked under tabs (not shown) onthe back of the spring, thus preloading the spring and creating a stablesub-assembly. The shield assembly would be top down assembled into thebottom housing of the infusion device prior to the button sub-assemblyby pressing a pivot means, such as a main bar (not shown) of the shield1030 into two sets of snaps (not shown) within the lower housing tocreate the pivot. One arm of the spring can be released to press on thebottom housing, and one arm of the spring can be locked under tabs onthe back of the spring, thus “energizing” the safety shield.

The safety embodiment shown in FIGS. 123 through 127 is another exampleof a passive safety system that completely covers the needles 1040 withmaterial. The material is constructed as a metal stamping, which allowssmaller wall thickness. In doing so, the embodiment requires only twoadditional parts having a high strength to fail. Also, the minimal forceapplied to the skin by the shield is farther away from the needlecontact point than other embodiments. The shield 1030 however, requiresa degree of space within the device, which can make the device longer,and the shield 1030 presses on the skin during delivery. The shieldopening 1035 further removes a large adhesive surface near the needles1040. Also, as with most compressed spring mechanisms, such springs canbe subject to creep, and there can be concerns regarding springselection and the ability to construct pivot tubes as required.

The above embodiment can be further provided with an improved lockingmechanism as the bucket, or shield 1030 travels from retracted toextended positions. The shield in this case, is a molded part andinstead of having a flexible lock, the pivot of the shield can “ratchet”around and thereby prevent reverse rotation. FIG. 128 is a perspectiveview of an improved safety shield embodiment of an infusion devicebefore activation, and FIG. 129 is a perspective view of the safetyshield feature after activation.

As shown in FIG. 128, a button 1050 and not the housing holds a shield1055. When the button 1050 is pressed, the shield 1055 is released andrests on the skin substantially as described above. As the device isremoved from the skin surface, the spring (not shown) flips the shield1055 and a ratchet mechanism 1060 at the pivot point engages a catch1061 on the device body as it rotates, such that the ratchet mechanism1060 holds the shield 1055 in place. FIG. 130 illustrates the ratchetmechanism 1060 in greater detail. Ratchet teeth 1059 are present on theshield 1055 arm 1057, and a corresponding wedge, or catch 1061 islocated on the device. Any partial rotation is now locked.

The ratchet can provide teeth 1059 sufficiently large enough to resist adefeating load, however they are not so large as to protrude from thebottom of the device and into the user. Additionally, to achieve thesegoals, the ratchet 1060 does require recessing the shield 1055 into thedevice, thereby adding to the height of the device. A sufficient springforce is provided to drive the shield 1050 incrementally over theratchet 1060, however care must be given to force balance between fulltravel and creep issues. Also, final assembly is somewhat more intricateas the spring has no natural place to be held and must be loaded in thedevice at the time of assembly, which also requires interleaving thebutton between the manifold and shield.

The ratchet lock provides yet another passive safety embodiment whichcompletely covers the needles with material and can be molded of highstrength parts. The embodiment requires only two additional parts andwill lock on full or partial deployment for robust safety. The forceapplied to the skin surface is further away from the needle site thanwith other embodiments, however, the embodiment requires a degree ofspace within the device which can make the device longer. As with theabove embodiment, the shield 1055 presses on the skin during deliveryand the shield opening removes a large adhesive surface near theneedles. Also, as with most compressed spring mechanisms, such springscan be subject to creep and the spring must be loaded during assemblyinto device. A ratchet lock so close to the pivot point also requiresvery high strength.

Another improved safety embodiment of the present invention is a passivefully enclosed pull out design embodiment as described below. FIGS. 131and 133 are perspective bottom views of a device illustrating anembodiment of a safety shield feature of an infusion device beforeactivation, and FIGS. 132 and 134 are perspective bottom views of adevice illustrating the safety shield feature after activation.

In the use of the embodiments of FIGS. 131 through 134, the userprepares and uses an infusion device 1060 substantially as describedabove. When the device is removed from the skin, an adhesive patch 1062attached to a shield 1065 will pull the shield 1065 out and lock it intoplace before the adhesive patch 1062 releases the skin surface. Thesafety housing, or shield 1065, is provided which includes a flatsurface portion that is in contact with the patient's skin. The flatsurface includes the adhesive patch 1062 disposed thereon such that whenthe device is removed by the patient from the skin, the adhesive patch1062 will act to deploy (i.e., retract or extract) the shield 1065 fromthe interior of the device, thereby shielding patient needles 1067 whichotherwise would be exposed upon removal of the device from the patient.The extended safety shield 1065 is then locked into place and preventsaccidental injury or exposure to the patient needles.

The shield 1065 is a stamped metal part that fits within the device 1060and is held in place by a button 1064 to prevent the shield 1065 fromactivating prior to use when the adhesive liner and needle cap (notshown) are removed. The adhesive patch 1062 is provided in substantiallytwo parts, one on the bulk of the bottom surface of the device 1060, andone on the bottom surface of the shield 1065. When the device 1060 isremoved, the two patches move independently and the shield 1065 is nowmobile since the button 1064 has been pushed. In the embodiment shown inFIGS. 133 and 134, a number of guide slots and tabs 1063 are providedwith the shield 1065. The shield 1065 is pulled out until it becomestrapped between the top of the slots and the tabs 1063, and is therebylocked into position by the angled tabs on the shield 1065.

The assembly of this embodiment can be snap fit into the device from thebottom. The button is also snap fit into place, as it is required toengage the initial lock. The pull out embodiment is yet another passivesafety embodiment that is provided as a single part and provides a goodlock which will not crush under human loads. However, the embodimentrequires a degree of space within the device, and can be difficult toexpose as it requires a large adhesive area that floats at the needlesand which includes at least one non-adhesive covered hole at the bottom.This also results in a large travel required, and yet provides limitedcoverage on the backside. Also, interference such as a finger couldprevent deployment upon removal.

Another improved safety embodiment of the present invention is a passivetorsion spring retraction design as described below. FIG. 135 is aperspective view of an embodiment of a safety shield feature of aninfusion device in an initial position, FIG. 136 is a perspective viewof the safety shield feature in an in-use position, and FIG. 137 is aperspective view of the safety shield feature in a final retractedposition.

The embodiment includes a preloaded internal torsion spring 1070 whichrests on a peg 1074 on a manifold 1076. Two springs could be used ifnecessary. When a button 1075 is pushed, the manifold 1076 is releasedand the spring falls off block 1071 and pushes a drive peg 1072 on themanifold 1076 to push the manifold 1076 downward to a seated position atthe appropriate velocity. When the device is exhausted and it is removedfrom the skin, one of two things can occur. First, the manifold 1076which is designed having extra over-travel, continues forward and thespring 1070 slips off the drive peg 1072, flips through 180 degrees, andcatches a retraction peg 1074 on the manifold 1076, lifting the manifold1076 thus retracting the needles (not shown). In an alternate version ofthe embodiment, the manifold 1076 is allowed to move sideways slightly,thus releasing the spring 1070 from the drive peg 1072 (which issomewhat shorter than the retraction peg 1074) to flip to the retractionpeg 1074 on the manifold 1076, lifting the manifold 1076 thus retractingthe needles.

The moving end of spring 1070 should have sufficient clearance to makethe 180° rotation but avoid the risk of causing injury as the arm of thespring passes from the drive peg 1072 to the retraction peg 1074.However, once retracted, the spring 1070 holds the manifold 1076 andneedles up and disables the device. The embodiment also requires noadditional parts.

As with the embodiments described above, this is a passive safetymechanism in which the manifold is the trigger and no additional partsare required. No additional forces are applied to the skin duringinjection, and the needles are safely held internally after use. Unlikethe pull out designs, this embodiment does not affect adhesive presenceat needles. However, clearance is required to avoid possible injury tothe user due to the moving arm of spring 1070. Also, as with mostcompressed spring mechanisms, such springs can be subject to creep, andthere can be concerns regarding spring dimensions and force profiles.

Other improved safety embodiments of the present invention includepassive hinged shield design embodiments as described below. FIG. 138 isa perspective view of an embodiment of a safety shield feature of aninfusion device in a spring-driven hinged position, FIG. 139 is aperspective view of a safety shield feature in an adhesive-driven hingedposition, FIG. 140 is a perspective view of a safety shield with acircular integral buckle spring held in a retracted position, and FIG.141 is a perspective view of the buckle spring in an activated position.

In FIGS. 138 and 139, a hinged shield 1080 and 1085 is shown,respectively. When on the device, the hinged shields 1080 and 1085 areflat. The shields 1080 and 1085 are locked flat until buttons 1082 and1086 are pushed, respectively, in which case, the shields 1080 and 1085are released but an adhesive holding the device to the body secures theshields 1080 and 1085 in a flat position against the skin. When thedevice is removed from the skin, the shields 1080 and 1085 “pop” up asurged by spring elements 1081 and/or an adhesive surface 1083,respectively, and are locked into place by tabs 1087.

In each of these embodiments, the shields 1080 and 1085 can be a metalpart sufficiently hinged at one point 1089 to secure rotation from thedevice. The hinged metal shield 1080 is driven by spring elements 1081to an extended and locked position. Specifically, the shield 1080 can beconstructed having a number of bent arms of the spring elements 1081that act as springs against the surface of the device. The bent arms ofthe spring elements 1081 are loaded against the bottom housing of thedevice and the button 1082 locks the front of the springs, typically ata point farthest from the hinge 1089, in the retracted position. Whenthe button 1082 is pushed, the shield 1080 is free to rotate about thehinge 1089 but the skin keeps the shield flat. Upon removal of theinfusion device from the skin, either the bent arms of the springelements 1081 alone, or in combination with the adhesive 1083 asprovided with spring 1085, pulls the shields 1080 and 1085 outward andlocks it into place with a number of tabs 1087 at the front of thedevice.

The spring embodiments described above are typically constructed with anability to resist a defeating load, since each can be a long and/or thinpart. Additionally, the springs 1080 and 1085 are adapted to provide asuitable amount of protection, even with a long term load and a longtravel. Once engaged, the springs 1080 and 1085 are also sufficient tohold on the hinge 1089 after engagement as required.

As shown in FIG. 140, an alternate version of the above embodimentincludes a shield 1090 having a natural hinge which acts as the spring.The shield 1090 is held in the position shown in FIG. 140 by a pushbutton 1091. Once released, the shield 1090 is biased to the shape shownin FIG. 141. Therefore upon activation and removal of the device, thespring 1090 is activated into the shape shown in FIG. 141 through theaction of a natural hinge, covering the needles (not shown). The base ofthe device can further include at least one notch that can lock the rearedge of the shield 1090 as it travels.

The hinged shield embodiments described above provide another entirelypassive, single piece safety shield, which is simple to assemble andactivate with a snap of the button. The features also ensure the devicemaintains a low profile. However, the embodiments include flex elements,and requires a balance between obstructed views and part stiffness.Access to the needles still exists somewhat through an opening, and thespring can be easy to defeat in some cases. Also, the embodiments applyloads to the skin at the needles during delivery and relies to a greatdegree upon hinge integrity.

Still another passive design for shielding needles in a micro infusiondevice is that of rotating the needles either back out of the user orallowing the needles to “over rotate” to a safe position when the deviceis removed from the skin by the user. In the improved rotational shieldembodiment shown in FIG. 142, the primary feature is the use of rotationto embed needles 1101, and the use of the same or similar rotation“path” to remove the needles 1101 once a skin surface 1104 is removed.In the embodiment shown in FIG. 142, a single needle-securing arm 1100is rotated about a first axis 1102. As the needles 1101 contact the skinsurface 1104, the needles 1101 are seated and travel about the axis 1102is stopped. Upon completion and removal of the device from the skinsurface 1104, the travel about the axis 1102 resumes, carrying theneedle-securing arm 1100 back into the device (not shown). Theneedle-securing arm 1100 can also be rotated about a second axis 1106 tofurther shield the needles 1101 after use.

As noted above, one desirable feature of an infusion device is that of acontinuous fluid path, which is preferred since it has the potential toreduce the number of sterile barriers and simplifies the manufacture ofthe device. Thus, an embodiment that includes rotating the needles 1101into the users skin 1104 via the needle-securing arm 1100 facilitatesthese advantages. This embodiment further provides the rotation of theneedles 1101 into the skin 1104 to embed them, and then allows theneedles 1101 to “over rotate” to a safe position when the device isremoved from the user's skin 1104. This over-rotation capitalizes on thesingle path the needles 1101 are traveling and can be employed either asa passive or an active safety system. Additionally, the mechanism hasthe potential to provide safety while not compromising the integrity ormanufacturability of the fluid path from the drug reservoir to theneedles 1101.

Another embodiment of a passive safety mechanism for a micro infusiondevice provides for the unloading of the activation spring upon removal.As noted above, such an infusion device uses an array of needles todeliver subcutaneous injections. These are fired by means of a springinto the patient at the velocity necessary to penetrate the skin layer.After the infusion has taken place, it is desirable upon removal of thedevice from the patient to shield the now-exposed needles in somefashion in order to prevent needle-stick injuries during subsequenthandling. If the driving spring can be unloaded or altered in some way,the needles can easily return back inside the housing of the devicewhere they will no longer pose a threat. In this embodiment, an arm isprovided, comprised of a bendable beam which can be loaded by means of acam and made to function as the spring for firing the needles. FIGS. 143through 146 illustrate an embodiment for accomplishing this task with asingle additional part.

As shown in FIGS. 143 through 146, a cross-sectional view is provided ofthe device including the cam-arm mechanism. The mechanism includes anarm 1110 having at least one follower 1112 extending from the arm andslidably coupled with a cam opening 1114. The arm further includes apatient needle manifold 1116 at a distal end, which is releasably heldin place by a trigger mechanism 1118. The cam opening 1114 is providedwithin a slidable member 1124. There are four basic states that theembodiment will see in use, all of which are depicted and described ingreater detail below.

In a first, or ready position shown in FIG. 143, the arm 1110 is at restand the assembly is ready for activation by the user. This is typicallythe assembled and shipped configuration of the product. In a second, orspring cocked position shown in FIG. 144, a button (not shown) isactivated by the user and moves the member 1124 to the right. As themember 1124 is moved to the right by a force applied to pin 1120, thearm 1110 remains stationary and is driven into a deflected position bythe movement of the cam opening 1114 about the stationary follower 1112.Since the pin 1120 and trigger 1118 are both attached to the button,each shift, placing the arm 1110 into this bent state by means of thecam opening 1114 and follower 1112. The spring is armed in this mannerby the user at the time of use, which has the advantage over apre-loaded assembly of eliminating the stresses and creep associatedwith a loaded spring. In this state, the trigger 1118 and latch 1122 areengaged and ready to fire by the user shortly before use.

In a third, or fired position shown in FIG. 145, further movement of thebutton has now moved the trigger 1118 far enough forward to unload thespring (i.e., release the arm 1110), driving the needles 1116 into theskin surface 1117. The latch 1122 has also now triggered via an openingprovided in the member 1124, allowing the arm 1110 and member 1124 toboth rest upon the skin surface 1117. The moment coupling of thefollower 1112, cam opening 1114, and residual spring in the arm 1110apply light pressure to the skin surface 1117.

In a fourth, or safe position shown in FIG. 146, the device has beenremoved from the skin surface 1117 and the member 1124 has rotated dueto the coupling of follower 1112 and cam opening 1114. This allows thearm 1110 to relax again to its original state, with the needles 1116retracted into the housing. The entire above mechanism can be disposedwithin an infusion device. An additional use of a cam/follower action inuse with a device is shown in FIG. 147, which illustrates an examplewherein a threaded member is used to load the springs used to cam thepatient needles into and out of the patient, as well as pressurize thereservoir contents.

Specifically, FIG. 147 illustrates an embodiment having a twist, orthreaded member 1125 to load spring(s) 1126 within the device. Thesprings 1126 are secured by a pin or button 1127 and when released,forces element 1129 forward, wherein a pin 1131 riding in a slot withinelement 1129, is forced downward and subsequently upward, correspondingto the slot within element 1129. Forcing the pin 1131 downward furtherforces a pivoting reservoir and needle assembly 1133 downward. Furthermovement of element 1129 forces pin 1131 upward and, with assistancefrom spring 1126 in contact with the assembly 1133, forces the assembly1133 upward.

As noted above, a passive safety system is most desirable, however,active safety systems are also functional and can be used in severalapplications. Also as noted above, with respect to safety systems thereare typically three options, including retracting the needles into thedevice, shielding the needles to remove access, and destroying theneedles in a way that prevents needlestick injuries. A number of passivesafety mechanisms have been described in detail above. A number ofactive safety mechanism embodiments of the present invention are nowdescribed in greater detail below.

An improved flip-shield safety mechanism embodiment of the presentinvention is shown in FIGS. 148 and 149. The function of the device issubstantially the same as above except when the device is removed, theuser flips a shield 1130 down and locks the shield 1130 in place toprevent needles 1135 from being accessed.

As shown in FIGS. 148 and 149, the shield 1130 is a substantially flatpiece of either plastic or metal, which is held in place by a pressusing a detent 1137 at the edge of the device. When the device is on askin surface during use, the shield 1130 is essentially flat. Afterremoval, the user grasps an extended tab of the detent 1137 on theshield 1130 and flips the shield 1130 about hinge 1139 to “crush andcover” the needles 1135. A lock (not shown) can also be provided suchthat the shield 1130 is irremovably secured with the device when closedafter use. When the shield 1130 is locked in place, both the needles1135 and needle opening are completely covered and locked.

The assembly of this embodiment can include a snap fit over the pivot,and press fit into an initial position. This can be done very early inmanufacture, such that it is in place and on the bottom of the devicewhile the rest of the device is assembled. An adhesive can also bedisposed on top of the shield 1130. Such an active safety mechanism isprovided by a single part, and has a simple assembly having a lowprofile and providing robust protection. However, the mechanism isactive, which requires an extra user step. Also, adhesive on the shield1130 can cause the device to float, and crushing the needles 1135 can beproblematic. Additionally, the pivot 1139 must be carefully placed toget full rotation and avoid incomplete locks.

As noted above, the improvement embodiments of safety mechanisms can beprovided in a number of versions, including a mouse-trap type safety, aneedle lift-and-cover type safety, and a rotating needle manifold typesafety. Both passive and active mechanisms are described in detailabove, however, several mechanisms can be provided as either active orpassive. A number of active/passive safety mechanism embodiments of thepresent invention are described in greater detail below.

In regard to the passive safety embodiments described above, severalembodiments, such as the needle lift-and-cover embodiments can also beprovided as active systems that the user employs, but which areinexpensive to manufacture and are very robust in use. For example, inthe needle lift-and-cover embodiments the force needed to embed theneedles by the drive spring is potentially high. Hence, overcoming theseforces by the user in an ordinary active safety system may likewise behigh and the potential for incomplete shielding of the needles is apossibility. However, several of the lift and cover embodimentsdescribed above as passive safety embodiments are advantageous in thateach offers a ramp. Therefore, where applicable as active safetymechanisms, lift and cover embodiments can each offer a ramp to gain amechanical advantage over the drive spring to lift the needles out, andalso includes the potential to dislodge the drive spring completelywhich greatly eases the forces required by the user to shield thedevice. A final advantage in both the active and passive mechanisms isthat these concepts can facilitate deployment of a transverse barrierwhich is integral to the ramp structure, and therefore inexpensive tomanufacture, simple to use, and robust in use.

In another improved safety embodiment which can be provided as either anactive or passive mechanism, a needle bending safety mechanism can beprovided. In this embodiment (not shown), the mechanism can include aplate with a hole in which the needles are passed through during use anddelivery. After use, either in an active or passive manner, the platecan be moved such that the edge of the hole in the plate would exert ashearing load on the very small gauge needles and bend them sideways,while at the same time covering them.

However, care must be taken to avoid breaking the needles and varyingdegrees of force can be required to bend the needles, as they should bebent very close to the mounting point where there is very little momentarm. This embodiment can be provided as either an active or passivemechanism, and include a simple single piece assembly with a lowprofile.

In still another improved safety embodiment which can be provided aseither an active or passive mechanism, a bi-stable leaf spring mechanismcan be provided, having a single spring which can both drive and retractthe needles. By using either a thin piece of plastic or metal, a biasedsystem can be created that would work in either direction. With abi-stable spring, the user would only need to overcome the stableresistance, then the “snap” to the other stable state would provide highvelocity seating. Conversely when the device was exhausted, the userwould only need to exert the same small force and the device wouldretract the needles.

In yet another version of this embodiment, a thin plastic component (notshown) can be provided and supported on one end and compressed slightlyfrom the other. When a moment is applied to the compressed end, theplastic will snap through to the more stable configuration. When themoment is released, the plastic component flips back. Such bi-stablesprings can be provided as active or passive mechanisms, and can beconstructed as a simple single piece assembly having a low profile andproviding high velocities.

Most of the previous design embodiments can be made into an activeversion, which could simplify them in that the need to sense the skinwith a trigger would be obviated by the application of a deploymentforce by the user. There are also a myriad of concepts in whichretraction is accomplished via a direct force from the user on a buttonor other such component, which then moves the manifold with nointermediate spring or other component.

In addition to the improved safety embodiments described above, furtherimprovement embodiments of the present invention include improvedmanifold springs, improved fill mechanisms, improved packagingmechanisms, and improved end-of-dose indicator mechanisms.

As noted above, the patient needle manifold is typically urged forwardwhen released by one or more patient needle manifold springs disposedwithin the infusion device. An exemplary device is shown and describedin relation with FIGS. 37, 38 and 39. However, the manifold springs ofFIGS. 37, 38 and 39 can further include the improved springs of FIGS.150 through 156, described in greater detail below.

In FIGS. 150 through 156, several improved manifold spring embodimentsare shown. In FIGS. 150, 151 and 152, perspective views of a firstembodiment of an improved manifold spring are shown. FIGS. 150 and 151show the spring in a loaded, or flexed position, and FIG. 152 shows thespring in a released, or relaxed position. A spring 1140 includes afirst and second adjacent member 1148 and 1145 coupled to produce asubstantially acute angle when relaxed as shown in FIG. 152. When in aloaded position, the first member 1148 is secured within an arc 1144provided by the second member 1145. A large, perpendicular member 1142is provided on the first member 1148 to engage a push button within thedevice to release the first member 1148 from the arc 1144 and applypressure via a substantially curved element 1146.

In operation, the loaded spring 1140 is positioned above a needlemanifold 1151 within a device. The spring 1140 is positioned above theneedle manifold 1151, such as the manifold 520 in FIG. 34. Wherein FIG.34 illustrates the spring 581 provided to apply a force to the manifold520, in yet other embodiments of the present invention, the spring 1140can be positioned above the manifold 520 and provide a force to themanifold. In FIGS. 150 and 151 the spring 1140 is held in a loaded stateby the engagement between the first and second members 1148 and 1145.When the push button (not shown) is activated, the perpendicular member1142 is engaged by contact with a button member 1159, moving the secondmember 1148 away from the stationary first member arc 1144, until thesecond member 1148 is released. Once released, the substantiallycircular contact area 1146 of the second member 1148 drives the manifold1151. The circular contact area 1146 ensures spring to manifold contactis provided at a center point of the manifold 1151 throughout theexpansion of the spring 1140. Such contact further ensures propermanifold travel. Still other embodiments of the improved manifold springare shown in FIGS. 153 through 156 and perform substantially asdescribed above.

In FIG. 153, the securing arc 1144 of FIG. 150 is replaced with asubstantially larger member 1147 extending from a button engagementmember 1149. As the button engages the member 1149, the member 1147releases the spring and presses the manifold 1151 forward, substantiallyas described above. Likewise in FIG. 155, the securing arc 1144 of FIG.150 is replaced with an engagement between members 1141 and 1143 andwhen released, perform substantially as described above. Each includes asmall detent means to prevent accidental releases.

In FIGS. 157 through 163, an improved “through the button” fillmechanism and method is shown, which can be used with any of theinfusion device embodiments and improvements presented above.

Step 1, shown in FIG. 157, illustrates a filling process. A partialcross-sectional view of a device 1150 shows a push button 1153positioned adjacent to a reservoir opening 1154. A hole 2153 is includedin the push button 1153, which allows filling the device 1150 throughthe reservoir opening 1154 even after assembly. In step 2 shown in FIG.158, a valve assembly 1156 is assembled within the reservoir opening1154 after filling through the button hole 2153. The valve assembly 1156can be assembled through the hole 2153, therefore, to use the button1153 to actuate the valve 1156, the hole 2153 needs to be restricted insome manner. In step 3, a member 1158 is provided to close the buttonhole 2153 access, or window, to allow the activation of the valve 1156as shown in FIG. 159. Once closed, as shown in FIG. 160, the push button1153 is ready to be pressed, thereby activating the valve assembly 1156.

In an alternative embodiment of the present invention, the valve 1156can be inserted through the opening 2153, then rotated to complete step3. As shown in top views of the button 1153 in FIGS. 161 and 162, thevalve 1156 is constructed having a substantially oval profile, which canbe slidably inserted in a similarly shaped hole 2153 provided by thebutton 1153. The oval profiles are designed to be non-symmetrical byrotation as shown in the cross-sectional view of FIG. 163, such thatonce in position in the reservoir opening, the rotation of the valve1156 allows the valve flange to be perpendicular to the opening. Thisallows the push button 1153, even with the opening 2153, to push thevalve 1156 when the button 1153 is moved forward. This option eliminatesthe need for the member 1158 provided to close the button window 2153 toallow the activation of the valve in FIGS. 157 through 160.

Still other improvement embodiments are related to device filling andcontent indication. As shown in FIGS. 164 through 167, an end-of-doseindicator can be provided with the infusion devices described aboveallowing a user to see if the drug has been administered, and to alesser degree, what extent may have been administered.

In some infusion devices, it is not possible to have a transparentreservoir where the user can see completely through the reservoir.Generally, when transparent materials cannot be used with liquids due tochemical interaction, or water/gas transmission rates are to high, asolution can include the use of a combination of transparent andnon-transparent materials. The non-transparent materials can be anynumber of materials, such as a laminated material with aluminum forflexible requirements, or coated materials for rigid requirements. Theembodiment of the present invention described below includes a reservoir1160 that is composed of a flexible, non-transparent material for amembrane 1162, and a rigid transparent material 1164. A visibleindicator 1166 to distinguish between the beginning and the end of thedrug administration is also provided. This visible indicator can beeither the appearance or disappearance of a sign occurring at the end ofthe infusion.

As shown in FIGS. 164 and 165, a raised relief 1168 constructed of asoft material on the indicator 1166 is in contact with the flexiblemembrane 1162, and is some distance from the rigid transparent material1164 due to the contents of the reservoir. However, the raised relief1168 creates a visible distortion or outline 1169 in the flexiblemembrane 1162 which is visible through the transparent material 1164. Anexample of such an outline 1169 is shown in FIG. 164. Once the reservoir1160 is emptied as shown in FIGS. 166 and 167, the raised relief 1168 isflattened by contact with the rigid transparent material 1164 due to thelack of contents in the reservoir 1160. The distortion 1169 in theflexible membrane 1162 is thereby eliminated, as shown in FIG. 166. Theembodiment therefore can be used to provide a direct visualization ofthe fluid dispensed, however, still other embodiments can provide end ofdose indication in any number of ways including timers and pressurecontrols/sensors.

To provide the embodiment of the present invention described above, aflexible material is provided as the membrane 1162. At the beginning ofthe injection, the “flexible sign” of the raised relief 1168 is appliedon the flexible membrane 1162 and as such, the force applied to theraised relief 1168 is the force applied to the film 1162 and thereservoir contents, which yield to a great degree therefore littledeformation of the raised relief 1168 appears. At or near the end of theinfusion or injection, the membrane or film 1162 is in contact with thehard transparent part 1164 of the reservoir 1160, and the raised relief1168 is compressed against the reservoir and the sign of the raisedrelief 1168 disappears.

In yet another improved visual indication embodiment of the presentinvention, another feature can be incorporated into the micro infusordevice to visually indicate when the medication delivery is complete. Asnoted above, several designs of infusion devices include a needlemanifold in combination with similar components, and which move in thegeneral direction of a patient's skin for insertion. The needle manifoldthen moves away from the patient's skin for retraction. This feature, inassociation with the upper and lower case of the outer shell of thedevice, can be used for providing such an improved visual indicator.

During the infusion process, the lower case is attached to the patient'sskin while the upper case is the shell component furthest away from theskin. It is this upper shell which is generally visible to the patient,or person using the infusion device. Located within the infusion device,is a component commonly referred to as a needle manifold substantiallyas described above. Permanently fixed into this needle manifold are oneor more micro-needles, or very small cannula. This needle manifold isalso attached to the fluid reservoir in various manners to form acontinuous, leak-proof, fluid pathway. The pathway is provided to allowthe fluid to travel from the fluid reservoir, through one or more fluidcontrol devices, through the needle manifold and distal end of themicro-needles, and into a patient.

At or near the beginning of the infusion process for drug delivery, thecannula punctures and enters the patient's skin to deliver the fluid,liquid, gas or vapor medication provided by the reservoir. Themedication can be selected to be delivered into targeted regions belowthe epidermis of the patient. To puncture the skin so that drug deliverycan occur, the needle manifold is urged by manifold springs in adirection substantially perpendicular to, and towards the patient's skinsurface, and in a direction generally parallel with the long axis of thecannula. As noted above, the needle manifold motion may also be designedas a rotating mechanism, however, the protruding indicator elements ofthis improved visual indicator embodiment can still be incorporated. Ator near the termination of the infusion process, the cannula arewithdrawn from the patient by moving the needle manifold in a directiongenerally away from the skin and/or by moving the needle manifold in thedirection opposite to its previous motion.

The total distance of needle manifold travel in an example embodimentcan be approximately three to six millimeters (3 mm to 6 mm). Apreferred design feature however, is to minimize the height or“tallness” of the infusion device in which this travel occurs. For otherfunctional requirements, the needle manifold is typically one of thetallest components in the infusion device. In this sense, a “tall”direction is perpendicular to the skin surface in the area of infusiondevice placement. For these reasons and to accommodate the necessarymotion, the top surfaces of the needle manifold will be close to, or incontact with the inside surface of the upper case while in storage,prior to use, and before the needle manifold motion causes cannulainsertion into the skin. When the infusion process is started, theneedle manifold moves away from the inside surface of the upper caseduring cannula insertion, causing a gap or clearance between the uppercase and the needle manifold. When fluid infusion is complete, theneedle manifold and cannula are retracted, thus returning to theirstarting position. The embodiment of the present invention includes afeature disposed at the top of the needle manifold that can be visibleto the patient or user through a feature in the upper case.

In a first embodiment, the needle manifold can have a cylindricalprismatic or similar prismatic feature that can protrude from and/orabove the top surface of the needle manifold. This protruding featurecan be integrally molded with the needle manifold body, or it may be aseparate part attached to the needle manifold body. The protrudingfeature is a highly reflective and/or bright contrasting color tooptimize visibility.

Corresponding with the needle manifold's protruding feature describedabove, both in general location and approximate size, an opening can beprovided through the top case, or provided as a transparent window ormolded lens-shaped device fitted into or through the top case. Theprotruding feature on the needle manifold would slidably fit into orthrough the top case opening, or slidably fit into a concavely pocketedarea on the inside region of the transparent window. To accommodate apivoting or textural type indicator, a larger, rectangular, or ovalshaped window can be provided in the top case.

As noted above, the protruding feature on the needle manifold is ahighly reflective and/or bright contrasting color to optimizevisibility. In yet other embodiments, a simple colored indicator caninclude text, such as the word “Ready”, “OK”, or “Start”, which isvisible in the case opening or window.

Additionally, another embodiment having a two-position indicator ispossible by adding at least one additional part. This two-position, orpivoting, indicator can include the above text in quotations (i.e.,indicia) prior to infusion, and when the needle manifold has traveleddown and is in the return stroke, a spring integral or attached to thepivoting indicator, can flip the indicator to make visible additionaltext such as the word “End”, “Done”, or “Remove”. The moving featurewith the indicia may also slide relative to the needle manifold insteadof pivoting.

In use, the embodiment of the present invention described above allowsambient light to pass through the transparent lens or window in the topcase, which reflects from the protruding indicator surfaces locatedclose to or within the concave pocket of the window. The reflected lightis then transmitted back out through the window and is then received bythe user's eyes. Essentially, when the needle manifold is in the up, orretracted position, the indicator window of the infusion device appearsas a bright object surrounded by a clear lens. The indicator is visibleas a color that distinctly contrasts with the surrounding surfaces ofthe top case.

When the needle manifold is down, or in the “cannula inserted” position,the protruding indicator feature is some distance away from the window.Light passing through the window while in this operating mode hasnothing to reflect from and scatters inside the infusion device,therefore the window appears dark. In doing so, this embodiment of thepresent invention actually indicates the position of the needle manifoldand cannula, rather than indicating whether the fluid has beenpartially, or fully discharged from the infusion device and into thepatient. However, other methods of use can be used by the user tointerpret the visible changes in the indicator window.

The embodiments described above are commonly packaged for convenienceand protection. Therefore, in yet another improvement embodiment of thepresent invention, a packaging system is provided which allowsprefillable devices such as those described above to be sterilized,transported, decontaminated, and filled with contents, such as medicineas either a liquid, gas, powder, and the like. The devices themselvesare not decontaminated, but the packaging surface is.

The packaging system shown in FIGS. 168 through 175 comprises an arraytype package, or nest 1170, which maintains a number of prefillabledevices 1175 in a defined position (i.e., vertical), and providesexternal packaging which can be flexible, like a pliable bag 1185 and1190, or rigid, like a box 1180.

After production of any infusion device, including improved embodimentsdescribed above, the devices can be assembled into openings 1171 of theempty nest 1170 of FIG. 168 until full as shown in FIG. 169, orpartially full as shown in FIG. 170. Each opening further includes anumber of ribs 1196, described in greater detail below. Then an externalpackaging, such as bag 1185 and bag 1190 (as shown in FIG. 174illustrating a complete packaging example), or box 1180 and bag 1190 (asshown in FIG. 175 illustrating a complete packaging example), isprovided to guarantee integrity against bacterial contamination. The bag1185 can be provided with an internal vacuum, and bag 1190 can beprovided with or without an internal vacuum. The rigid box 1180 can beprovided having a Tyvek, paper, film or rigid cover, and the bag 1190can be provided with or without an internal vacuum. Typically, theexternal packaging can include still another package that is added toprevent dust (i.e., a dust cover) from coming into contact with the boxor bag. The complete packaging (i.e., the nest 1170 and externalpackaging) can be sterilized by gamma radiation, ethylene oxide, E-beam,or other appropriate sterilization method.

When the devices 1175 need to be filled, the complete packaging isexternally decontaminated to prevent bacteria from entering the fillingroom which is an aseptic environment. Then the external bag 1190 (i.e.,the dust cover) is removed and the box or bag (i.e., 1180 or 1185) ofthe external packaging is opened to remove the nest 1170 and the nestwith devices 1175 is placed on a filling machine (not shown) to thenfill the devices 1175.

To ease the filling process, the filling machine can raise the devices1175 as shown in FIG. 171 using the ribs 1195 and 1196, and largeopenings 1198 provided in the bottom of each opening 1171 of the nest1170 as shown in a top view of the nest in FIG. 173. The ribs 1195 and1196, and openings 1198 are provided to improve the laminar air flowaround the devices 1175 and provide a support for the device 1175 if aforce is required on the top of the device. The ribs 1195 further can beused to hold the devices 1175 and ribs 1196 can be used to center thedevices. For specific filling processes, the devices 1175 need to bemaintained in an accurate position to have a filling head of a fillingmachine (not shown) align with the devices 1175 as indicated by thearrows in FIG. 171. Moving the devices upward as shown in FIG. 171allows the filling machine to have additional fixtures to align thedevices 1175 carefully.

Currently, packaging exists for use with syringes, where the syringesare placed in a nest composed of a plastic plate and chimney, and anexternal packaging is provided and constructed of a rigid box. Theembodiment of the present invention does not include a plate or chimney,but simply an arrangement of ribs 1195 and 1196. The use of ribs 1195and 1196 ensures a low front surface, and allows the laminar air flowpresent in the room to flow around the devices 1175 and improve thequality of filling in addition to providing the lifting abilitydescribed above.

Other benefits associated with the embodiment described above includethe ability to have the flexible bag 1185 instead of the rigid box 1180as part of the external packaging, then allowing a vacuum in the bag1185 to provide a visual indicator of the package integrity. In thisversion, a lost vacuum indicates no integrity. Additionally, theflexible bag 1185 is less expensive to provide than the box 1180. In apreferred embodiment, a configuration is provided with the nest 1170 andthe external bag 1185 having no vacuum, and an added second bag 1190also without vacuum to prevent dust from coming into contact with thefirst bag.

Although only a few exemplary embodiments of the present invention havebeen described in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention.

What is claimed is:
 1. A device for delivering a medicament into a bodyof a patient by injection into or through a skin surface of saidpatient, comprising: a housing having a bottom surface adapted tocontact a skin surface of a patient; an injection needle adapted forpenetration of said skin surface and for movement through a needleaperture; a reservoir, disposed within said housing, said reservoir influid communication with said injection needle; and a safety memberadapted for movement away from said bottom surface of said housing, saidsafety member having a covering portion disposed about said needleaperture, and at least one shield protruding from said covering portion,said safety member having a first position wherein said shield of saidsafety member is initially disposed within said housing and saidcovering portion is substantially co-planar with said bottom surface ofsaid housing, and a second position wherein said shield of said safetymember is at least partially withdrawn from said housing and at leastpartially covers said injection needle; a spring element configured tobias said shield and covering portion of said safety member toward saidsecond position; and a rotatable door adapted to contact a skin surfaceof a patient and disposed upon said bottom surface of said housing andhaving a first position, which prevents movement of said safety member,and a second position, which allows movement of said safety member;wherein when said device is placed upon said skin surface of saidpatient and activated, said rotatable door is released and free torotate from said first position to said second position and said springelement is free to urge said safety member into said second position,whereby, as said device is removed from said skin surface, said shieldof said safety member emerges from said housing and at least partiallycovers said injection needle.
 2. The device as claimed in claim 1,further comprising a pressurization system for pressurizing saidreservoir.
 3. The device as claimed in claim 1, wherein said springelement comprises a flat spring disposed upon said bottom surface ofsaid housing and configured to bias said shield and covering portion ofsaid safety member toward said second position.
 4. The device as claimedin claim 1, wherein said spring element is disposed between said bottomsurface of said housing and said rotatable door.
 5. The device asclaimed in claim 1, wherein said spring element, shield and coveringportion are constructed as a single member.
 6. A device for delivering amedicament into a body of a patient by injection into or through a skinsurface of said patient, comprising: a housing having a bottom surface;an injection needle adapted for penetration of said skin surface and formovement through a needle aperture; a reservoir, disposed within saidhousing, said reservoir in fluid communication with said injectionneedle; and a safety member adapted for rotational movement along asubstantially arcuate path relative to said bottom surface of saidhousing, said safety member having a skin contacting portion disposedabout said needle aperture and substantially covered with adhesive, anda pivot, said safety member having a first position wherein said safetymember is secured against said bottom surface and is substantiallyco-planar with said bottom surface of said housing, said safety memberhaving at least one surface configured to contact and be held in placeby a device activation button to prevent rotational movement of saidsafety member while in said first position, and a second positionwherein said at least one surface configured to contact and be held inplace by said device activation button to prevent rotational movement ofsaid safety member is released by movement of said device activationbutton from said contact with said safety member, and said safety memberis rotated about said pivot and at least partially covers said injectionneedle; wherein when said device is placed upon said skin surface ofsaid patient and said device activation button is moved, said safetymember is released by movement of said device activation button and saidskin contacting portion of said safety member is temporarily adhered tosaid skin surface and when said device is removed from said skinsurface, said adhesion of said safety member to said skin surface issufficient to rotate said safety member about said pivot from said firstposition to said second position.
 7. The device as claimed in claim 6,further comprising a pressurization system for pressurizing saidreservoir.
 8. The device as claimed in claim 6, wherein said at leastone surface configured to contact and be held in place by said deviceactivation button comprises a detent disposed upon said safety member.9. The device as claimed in claim 8, wherein said detent is configuredto be secured by a movable shoulder of said device activation button.